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Starting and Lighting 

Troubles, Remedies and 
Repairs 

A Manual for the Location and Correction 
of Trouble in Automobile Electric 
Lighting and Starting Apparatus 

Including Wiring Diagrams of the Internal and 
External Circuits of Each Type of Equipment 


By 

HAROLD P. MANLY 

Author of “Automobile Starting and Lighting”, “Automobile 
Battery Care and Repair”, and “Automobile 
Ignition”. Editor of ‘ Brookes’ 

Automobile Handbook”. 


ILLUSTRATED 


CHICAGO 

FREDERICK J. DRAKE & CO. 
Publishers 









Copyright, 1922 and 1920 
By 

FREDERICK J. DRAKE & CO. 


Printed in U. S. A. 

v - > *> 

C 1 0 

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4> O 9 

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( 

xt-zizSS 

©CI.ABS65JJ5 

OCT 30 *22 


\ 




PREFACE 


Starting and Lighting Troubles, Remedies and 
Repairs is designed for use in electrical service sta¬ 
tions, battery stations, repair shops and garages in 
general; also for the car owner who makes his own 
repairs. 

Systematic methods are given for quickly locating 
the exact form of trouble that may be present. The 
work is completed by instructions for either the 
remedy or repair called for, these instructions being 
in such form that it is possible to perfori^. the opera¬ 
tions in a proper manner and with the least possible 
effort and time. 

The volume consists of three distinct parts: 

First, trouble location charts which, when the con¬ 
dition of the lights and starter is observed, tell of 
the steps necessary for finding the fault and for 
correcting it. 

Second, detailed instructions for making the cor¬ 
rect tests to determine the kind of fault that may 
exist in any of the several parts of the electrical 
equipment. An explanation of the construction and 
use of electrical testing equipment is also included. 

Third, diagrams of the wiring, both internal and 
external, are given. These diagrams show the ap¬ 
paratus employed since such equipment came into use 
in 1912. They are especially drawn for use in this ‘ 
class of repair work and are made uniform in style 
and symbols throughout. 


5 


6 


STARTING AND LIGHTING TROUBLES 


On the page facing each diagram is given a com¬ 
plete outline of the specifications and characteristics 
of the system illustrated. This description gives all 
the information required in handling the repairs. 

It is assumed that the reader has some knowledge 
of the principles of electric lighting and starting, 
such as given in the volume “Automobile Starting 
and Lighting.” However, if one is acquainted with 
electrical work of a general nature, such knowledge 
is not essential. 

The publishers will welcome suggestions from 
users of this book. It is the intention to add all 
necessary information and diagrams to future edi¬ 
tions as the development in this field may require. 

The Author. 


TABLE OF CONTENTS 


CHAPTER PAGE 

I Trouble Finding Charts. 9 

Lamps — Starter — Overloads—Dynamo—Bat¬ 
tery. 

II Testing Equipment. 34 

Inspection—Voltmeter, Ammeter and Test 


Lamps—Standard Electrical Tests. Sections 
1 to 99. 

III Circuit Testing. 57 

Open Circuit—High Resistance—Short Circuit 
Grounds — Resistance Test — Voltage Loss — 
Polarity Tests. Sections 100 to 149. 

IV Wiring Troubles . 83 

Short Circuit—Grounds—Open Circuit—High 
Resistance—Wrong Connections. Sections 150 
to 199. 

V Lighting System Troubles. 94 

Lamp Cases — Reflectors — Focusing — Bulbs 
and Sockets—Connectors—Use of Lamps— 
Lighting Switch—Fuses and Circuit Breakers. 
Sections 200 to 299. 

VI Dynamo Troubles. 109 

Dynamo Output—Examination—Sparking and 
Heating — Motoring the Dynamo — Brushes, 
Commutator, Armature and Fields. Sections 
300 to 399. 

VII Regulation Trouble. 148 

Testing Methods—Operating Principles—In¬ 
creasing Output—Decreasing Output—Instruc¬ 
tions for Adjusting—Limited Amperage Sys¬ 
tems — Constant Voltage Systems — Third 
Brush — Vibrating Relays — Constant Speed 
Governors—Rheostats—Various Kinds of Reg¬ 
ulation. Sections 400 to 499. 










CONTENTS 


CHAPTER PAGE 

VIII Cut-Olt Troubles .. 183 

Electromagnetic Type—Adjustment for Open¬ 
ing and Closing—Troubles and Remedies— 
Manual Types. Sections 500 to 599. 

IX Starting System Troubles . 192 

Starting Motor — Examination — Fluctuating 
Current—Running Free Test—Power Test— 
Troubles and Remedies—Starting Switches— 
Drive for Motors and Dynamos. Sections 600 
to 699. 

X Battery Troubles . 210 

Electrolyte — Cleaning — Use and Abuse — 
Mounting — Connections — Dead Cell—Rotted 
Case—Loose Parts — Sealing — Overheating— 
Conditions of Charge and Discharge—Poor 
Repairing—Results of Faults. Sections 700 
to 799 

XI Tables and Data . 227 

Resistance of Wires—Ohm’s Law—Wire Size 
for Lighting and Charging—Wire Size for 
Starters—Current Required by Lamps—Re¬ 
quired Battery Capacity—Torque Required for 
Starting—Output Rates and Regulation of All 
Makes and Types of Equipment. 


Adlake 

Allis Chalmers 

Aplco 

Autolite 

Bijur 

Bosch 

Deaco 

Delco 

Detroit Ward 
Leonard 
Disco 
Dyneto 
Entz 
Esterline 
Ford 
Garford 


Gray & Davis 
Hartford 
Heinze 
Jesco 

Leece Neville 
North East 
Remy 
Rushmore 
Simms Huff 
Splitdorf 
U. S. L. 

Vesta 
Wagner 
Ward Leonard 
Westinghouse 


XII Wiring Diagrams and Information 


240 








STARTING AND LIGHTING 
TROUBLES, REMEDIES 
AND REPAIRS 


CHAPTER I 

TROUBLE FINDING CHARTS 
HOW TO USE THE CHARTS 

In case of trouble in the electrical system it is 
first necessary to decide whether it affects the light¬ 
ing or starting functions. If it affects the lights, 
they will act in one of four ways; remain out, burn 
dimly, flicker or burn out. Furthermore, the trouble 
will be found in all of the lamps or only in a part of 
them. With the above points determined, the proper 
Chart to follow is indicated in the outline which 
follows on page 12. 

If the trouble affects the engine starting, it will 
cause a complete failure to crank or slow cranking. 
Each condition is covered by a Chart. 

Should it already be known that there are over¬ 
loads in the system, or that the charge rate to the 
battery is incorrect, or that trouble is shown in the 
condition of the battery itself, it will not be neces¬ 
sary to consider the lighting or starting conditions, 
but Charts may be followed which cover the troubles 
just mentioned. 


0 



10 STARTING AND LIGHTING TROUBLES 

After turning to the Chart indicated by the letter 
which appears after the description of the kind of 
trouble present, follow the numbered instructions 
of the Chart in the order that they are given. 

Should the test or examination called for by the 
Chart not be familiar to the user of the book, it will 
be noted that after each item there are numbers in 
parenthesis. These numbers refer to sections in the 
pages describing the methods of testing and repair. 
That numbered section, or the several sections shown, 
should be referred to for a complete explanation 
of the work to be performed. 

Should the user wish to make tests or repairs on 
certain parts of the equipment without first using 
the Charts for location of trouble, the list given on 
pages 52 to 56 will indicate the sections which cover 
any particular case. 

SYSTEMATIC TEST 

The operating condition of the entire lighting and 
starting systems may be checked by the following 
test which is divided into four parts. The test 
should be made in the order given, from number 
1 to number 4. 

In the left hand column is given the number of the 
test. In the next column toward the right is given 
the description of the test to be made. In the third 
column is given a list of the conditions that may be 
found, both right and wrong conditions being named. 
In the right hand column, and directly opposite each 
of the possible conditions, is given the chart or 
further test to be used provided that a certain condi¬ 
tion has been found. 


Operate engine starter Slow cranking Chart L 


SYSTEMATIC TEST 


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TEST OF ELECTRICAL. SYSTEM 


TROUBLE FINDING CHARTS 


12 


STARTING AND LIGHTING TROUBLES 




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SPECIFIC GRAVITY TOO LOW 





























TROUBLE FINDING CHARTS 


13 


CHART A. 

Some Lamps Out, But Not All. 

1. Lamp case loose on supports (206). 

2 . Lamp connector loose, dirty, or shorted inside, 

spring broken or jammed, turned wrong or 
grounded on lamp case (214, 215). - 

3 . Lamp bulb burned out (209), or of wrong base 

type (211). 

4 . Bulb socket loose or dirty, spring broken or 

jammed (214, 215). 

5 . Wires loose inside of lamp case (103-105, 113- 

120, 208). 

6. If trouble has not been located, follow Chart C. 


CHART B. 

All Lamps Out With Engine Idle 

Lamps light, either dimly or bright, with engine 
running. 

1. Test the specific gravity of the battery. 

If gravity is below 1.150, follow Chart P. 

If gravity is about 1.150, use this chart. 

2 . Examine the battery. 

(a) poor ground connections (741). 

(b) corroded terminals (714). 

(c) terminals or bars loose (781). 

3 . Test lines from battery to lighting switch and 

from battery to ground for open circuits 
(103-105, 160-162). 

4 . If trouble has not been located, follow Chart C. 


14 


STARTING AND LIGHTING TROUBLES 


CHART C. 

All Lamps Out With Engine Running or Idle 

1. Test the specific gravity of the battery. 

If gravity is below 1.150, follow Chart P. 

If gravity is above 1.150, use this chart. 

2 . Test wiring with tester at battery (155). 

3 . Examine lighting fuses. 

(a) burned out (230). 

(b) poor contact in clips (231). 

(c) loose connections. 

4 . Examine lighting circuit breaker (240). 

(a) open, not re-set. 

(b) contacts dirty. 

(c) disconnected or burned out (103-105). 

5 . Examine terminals, lighting switch and lines. 

(a) dirty, shorted or grounded (113-120, 

156-159). 

(b) disconnected or loose (103-105, 108-110, 
160-162). 

6. Examine lighting lines, switch to battery. 

(a) broken or disconnected (103-105, 160- 
162). 

(b) poorly made joints (108-110, 163-164). 

(c) shorts or grounds, loose strands, cutting 

clamps, sharp corners (113-117, 119, 

120, 156-159). 

7. Examine lighting switch internally (104, 105, 

109, 110, 222). 

(a) contacts dirty, bent or burned. 

(b) parts loose. 

(c) short circuits. 

8. Follow wiring for wrong connection (154). 

9. If trouble has not been found, follow Chart B. 



TROUBLE FINDING CHARTS 


15 


CHART D. 

Same Lamps Burn Dimly, But Not All 

1. Lamp case loose on supports (206). 

2 . Lamp connector loose, dirty or shorted inside, 

grounded on lamp case (214). 

3. Examine lamp bulb. 

(a) old or of poor quality, carbon filament 
(209). 

(b) low candlepower (212). 

(c) high voltage (213). 

4 . Bulb socket loose or dirty (215). 

5. Examine lamp reflector. 

(a) loose in case (207). 

(b) tarnished' (204). 

6 . Examine lamp. 

(a) out of focus (202). 

(b) tilted wrong (203). 

7. Loose wires in lamp case (103-105,113-120, 208). 

8. If trouble has not been located, follow Chart F. 



16 


STARTING AND RIGHTING TROUBLES 


CHART E. 

All Lamps Burn Dimly With Engine Idle 

Lamps light brightly with engine running. 

1. Test the specific gravity of the battery. 

If the gravity is below 1.150, follow Chart P. 
If the gravity is above 1.150, use this chart. 

2. Examine the battery. 

(a) poor ground connection (741). 

(b) corroded terminals (714). 

(c) terminals or bars loose (781). 

(d) liquid at low level (701). 

(e) battery loose in case (730). 

3. Loose or dirty connections at ammeter (108-110, 

163-164). 

4 . Follow wiring for wrong connections (154). 

5. If trouble has not been located, follow Chart F. 


TROUBLE FINDING CHARTS 


17 


CHART P 

All Lamps Bum Dimly With Engine Idle or Running 

1. Test the specific gravity of the battery. 

If gravity is below 1.150, follow Chart P. 

If gravity is above 1.150, use this chart. 

2. Make general test of wiring with tester at bat¬ 

tery (155, 107). 

3. Lighting fuse clips loose or dirty (231). 

4 . Lighting circuit breaker contacts dirty (240). 

5. Examine terminals at lighting switch and in 

lighting lines. 

(a) loose, wet, oily or dirty (113-120, 156- 
159). 

(b) shorts or grounds (113-117, 119, 120, 
156-159). 

6. Examine lighting lines between switch and 

battery. 

(a) shorted or grounded by moisture, dirt, 
oil, loose strands, sharp comers or cut¬ 
ting clamps (113-117, 119, 120, 156-159). 

(b) poorly made joints. (108-110, 163-164). 

7 . Examine lighting switch internally (104, 105, 

109, 110, 222). 

• (a) contacts dirty or burned. 

(b) parts loose. 

(c) short circuits. 

8. Wire size too small, or length too great (Table 

H). 

9. Follow wiring for wrong connections (154). 

10. If trouble has not been located, follow Chart E. 


18 


STARTING AND LIGHTING TROUBLES 


CHART G. 

Some Lamps Flicker, But Not All 

1. Lamp case loose on supports (206). 

2 . Lamp connector has loose wire strands or 

broken spring (103-105, 215). 

3 . Reflector loose in case (207). 

4 . Lamp socket has loose wire strands or broken 

spring (103-105, 215). 

5. Loose connections or wires in lamp case (103- 

105, 113-120, 208). 


\ * 


TROUBLE FINDING CHARTS 


19 


CHART H. 

All Lamps Flicker 

1. Test the specific gravity of the battery. 

If the gravity is below 1.150, follow Chart P. 

If the gravity is above 1.150, use this chart. 

2. Lighting fuse clips loose or dirty (231). 

3. Examine lighting lines, switch to battery. 

(a) loose connections, poorly made joints, 
broken under insulation (103-105, 160- 
162). 

(b) shorts or grounds, loose strands, sharp 
corners, cutting clamps (113-117, 119, 
120, 156-159). 

4 . Examine lighting switch for bare wires or 

loose parts (108-110, 222). 

5 . Examine battery 

(a) poor ground connections (741). 

(b) corroded terminals (714). 

(c) terminals or bars loose (781). 

(d) connections reversed (126, 127). 

(e) battery old (753). 

6. Examine charging circuit. 

(a) wires broken, disconnected, loose, poor 
joints (103-105, 108-110, 160-164). 

(b) wires shorted or grounded, dirty termi¬ 
nals, loose strands (113-117, 119, 120, 
156-159). 

(c) loose connections at ammeter. 

7. Examine dynamo commutator and brushes. 

(a) commutator mica high, commutator 
rough, or loose bar (341-343, 345). 

(b) brushes too short, tension too light (323, 
325). 


V 


20 STARTING AND LIGHTING TROUBLES 

8. Examine magnetic cut-out. 

(a) connections dirty, wet, oily, loose (113- 
120, 501) 

(b) connections reversed (503). 

(c) adjusted wrong (506-510). 

9. Examine manual cut-out for burned contacts, 

loose parts (550). 

10. Dynamo drive slipping. 

(a) connection between engine and dynamo. 
(680). 

(b) overrunning clutch (683). 

11. Examine regulation system. 

(a) third brush too short, binding, loose, etc. 
(321-325). 

(b) vibrating relay connections loose, arm 
sticking, etc. (427, 428, 433). 

(c) centrifugal governor slipping (440, 442). 

(d) loose connections, etc., in other govern¬ 
ors (460-499). 

12. Test cut-out for open circuited winding (504, 

505). 

13. Test commutator and armature for open cir¬ 

cuit (362, 363). 

14. Test cummutator and armature for short circuit 

(362, 364). 

CHART I. 

Some Lamps Burn Out, But Not All 

1. Bulbs old or of poor quality (209). 

2. Bulbs of too low voltage (213). 

3 . Lamps used too much (216). 

4. Wrong connections in lighting lines cutting bat¬ 

tery out of circuit at times. 


TROUBLE FINDING CHARTS 


21 


CHART J. 

Any or All Lamps Burn Out 

1. Test the specific gravity of the battery. 

If the gravity is below 1.150, follow Chart P. 
If the gravity is above 1.300, follow Chart 0. 
If the gravity is between 1.150 and 1.300, use 
. this chart. 

2. Examine the battery. 

(a) poor ground connections (741). 

(b) corroded terminals (714). 

(c) terminals or bars loose (781). 

(d) liquid at low level (701). 

(e) one cell dead (751). 

3. Examine lamp bulbs. 

(a) old or of poor quality (209). 

(b) of too low voltage (213). 

4. Examine charging circuit. 

(a) wires broken, disconnected, loose, poor 
joints (103-105, 108-110, 160-164). 

(b) wrong connections (154). 

5 . Test dynamo voltage and output. See section 

showing wiring -diagrams. 

(a) third brush (410-419). 

(b) vibrating relay (420-433). 

(c) constant speed (442-444). 

(d) rheostat governor (445-450). 

(e) other systems (460-499). 


22 


STARTING AND LIGHTING TROUBLES 


CHART K. 

No Cranking 

No rotation or movement of starting motor (606). 

1. Crank the engine by hand. 

(a) if the crank cannot be turned, look for 
mechanical trouble in the engine or 
transmission. 

(b) if the cranking is very difficult it indi¬ 
cates lack of oil, tight bearings or 
similar trouble. 

2 . Test the specific gravity of the battery. 

If the gravity is below 1.150, follow Chart P. 
If the gravity is above 1.150, use this chart. 

3. See that the starter drive connection is free to 

allow the motor to turn. 

(a) drive connection (680). 

(b) screw shift of pinion (682). 

(c) overrunning clutch (683). 

4. Make sure that there is sufficient voltage at the 

starting motor terminals by connecting a low 
voltage test lamp between the motor and cable 
or by using a voltmeter (103-105). 

(a) open circuit in starting lines (160-162). 

5. Examine the starting motor for the following 

troubles. 

(a) commutator dirty (341, 612). 

(b) brushes worn short (325, 611). 

(c) brushes binding or loose in holders 
(322, 611). 

(d) brush circuit open, pig tail off (324, 


TROUBLE FINDING CHARTS 


6 . Test the starting motor for the following 
troubles. 

(a) armature or commutator grounded 
(361, 613). 

(b) field circuit open (381, 384, 614). 

(c) field connected wrong (128, 129, 381, 
389, 614). 

(d) armature open circuited at two opposite 
points (362, 363, 613). 

(e) armature short circuited (362, 364, 613). 

(f) field shorted or grounded (381, 386, 387, 

614 ). 


24 


STARTING AND LIGHTING TROUBLES 


CHART L. 

Slow Cranking' or No Cranking 

1. Crank the engine by hand. If the cranking is 

very difficult, it indicates lack of oil, tight 
bearings, etc., in the engine or transmission. 

2 . Test the specific gravity of the battery. 

If the gravity is below 1.150, follow Chart P. 
If the gravity is above 1.150, use this chart. 

3 . Note indications of high resistance by the action 

of lamps and horn (107). 

4 . Examine the battery. 

(a) poor ground connections (108-110, 163, 

' 741). 

(b) terminals dirty or corroded (714). 

(c) terminals or bars loose (780). 

5 . Examine the wires of the starting circuit. 

(a) terminals loose, dirty or corroded (108, 
110, 113-117). 

(b) wires shorted or grounded by moisture, 
dirt or oil (119, 120, 156-159). 

(c) loose strands or poorly made joints. 
(163, 164). 

6. Examine the starting switch for dirt, oil, mois¬ 

ture or shorts at terminals. 

7 . Examine the screw shift for the starter pinion 

(682). Shaft dirty or sprung. 

8. Note excessive sparking at the brushes with the 

motor running (605). 

9 . Examine the brushes by pressing on them with 

the starting switch closed (601). 

10 . Examine the condition of the commutator (602). 

11. Examine the armature bearings (603). 

12. Examine the interior of the motor case (604). 


TROUBLE FINDING CHARTS 25 

13 . If possible, allow the starting motor to run free 

with the drive disconnected and note the ac¬ 
tion as to speed and amperage drawn (609). 

14 . Note the flow of current while the motor is 

cranking the engine (608). 

15 . If the tests up to this point have indicated se¬ 

rious trouble in the motor, and if the shop is 
properly equipped, the motor may be removed 
and tested for power (610). 

16 . Examine the starter drive. 

(a) flywheel gear teeth .dirty, burred or 
broken. 

(b) gear shift rods bent or binding. 

(c) overrunning clutch worn, broken, bind¬ 
ing (683). 

17. Examine the starting switch. 

(a) open circuits or high resistance (651, 
652). 

(b) short circuits or grounds (653, 654). 

(c) contacts dirty, burned or bent, loose 
parts. 

(d) starting resistance out of circuit (656). 

(e) wiring connections wrong between 
switch and battery. 

(f) wires too long or too small (Table III). 

18 . Examine the starting motor brushes. 

(a) not fitted (321, 611). 

(b) light spring tension (323, 611). 

(c) position wrong (326, 611). 

(d) wrong material or size (327, 611). 

19 . On motor-dynamo built to open charging cir¬ 

cuit while starting, slow cranking may be 
due to failure to open the charge line. 

20. If the trouble is not located, follow Chart K. 


20 STARTING AND LIGHTING TROUBLES 

CHART M. 

X 

Overloads 

t. The battery may be overloaded because of oper¬ 
ating conditions. 

(a) engine starts hard. Test cranking by 
hand. 

(b) engine requires long cranking. Due to 
ignition, carburetor or valve trouble. 

(c) too many starts with short intervening 
runs. Adjust output (402). 

(d) lamps used too much or too many ac¬ 
cessories attached (216). 

2. Test the wiring for short circuits or grounds 

(113-117, 119, 120, 156-159). 

3 . Test for excessive load in the lighting or start¬ 

ing system (121). 

4 . If there is a discharge from the battery with 

all switches open, look for the following 

troubles (113-120). 

(a) starting switch terminals dirty, wet or 
otherwise shorted (653, 654). 

(b) lighting switch terminals dirty, wet, oily 
or otherwise shorted (221). 

(c) if the system is of double voltage type, 
test the current from each part of the 
battery (744). 

(d) magnetic cut-out sticking closed (502, 
503). 

(e) starting switch return spring broken. 

(f) wrong connections of wiring between 
battery and switches, see diagram. 

(g) starting switch parts loose or bent. 


TROUBLE FINDING CHARTS 


5 . If there is an excessive discharge with the light¬ 
ing switch closed, look for the following 
troubles. 

(a) lamp connectors shorted or grounded 
(113-120, 214). 

(b) bulbs of too high candlepower (212). 

(c) bulbs old or of poor quality (209). 

(d) shorts in lamp sockets (214). 

,6. If there is an excessive discharge with the start¬ 
ing switch closed, look for the following 
troubles. 

(a) motor housing dirty or wet (604). 

(b) ground or double short in commutator 
or armature (362. 364, 613). 

(c) ground or short in field winding (381, 
386, 614). 


7 ^ 


28 STARTING AND LIGHTING TROUBLES 

CHART N. 

No Charge or Low Charge Rate 

1. Test the output of the dynamo and check it 

against the correct current for the equipment 
being handled (301-303). 

2. If the equipment is of the double voltage type, 

test the current flow into each part of the 
battery (744). 

3 . Note that too much slow driving will cause the 

symptoms of low output as far as the battery 
condition is concerned (402). 

4 . Test the voltage at the dynamo or the amperage 

at the dynamo and if it is found that the 
dynamo is generating, but that the current 
does not pass through the battery, test the 
wiring and cut-out as in 5 to 8 below. If the 
dynamo voltage or current is low, go on with 
9 below. 

5. Examine the battery. 

(a) If the battery is completely discharged 
and dead, it will act as a short circuit 
and may prevent the dynamo voltage 
from building up. 

(b) if one cell is dry, it acts as an open cir¬ 
cuit in the system (751, 752). 

(c) There may be a poor connection from 
the battery to ground (741). 

(d) The battery is less efficient in very cold 
weather. 

Test the charging lines 

(a) open circuits or high resistance (103-105, 
108-110, 160-164). 


6. 


TROUBLE FINDING CHARTS 29 

(b) short circuits or accidental grounds 
(113-117,119, 120, 156-159). 

(c) ammeter burned out or disconnected. 

(d) charging fuse burned out or clips dirty. 

(e) poor charging contacts in starting 
switch (656). 

(f) check the connections with a wiring dia¬ 
gram. 

7. Examine the magnetic cut-out for the following. 

(a) dirty, wet, oily or loose parts (113-120, 

' 501). 

.(b) cut-out sticking (502). 

(c) windings open circuited (504, 505). 

8. Examine a manual cut-out for dirty, burned or 

bent contacts or for loose connections (550). 

9. Make the following examination of the dynamo. 

(a) test brushes by pressing on them with 
dynamo running (304). 

(b) note condition of commutator (305). 

(c) note condition of armature (306). 

(d) note whether there is excessive spark¬ 
ing at the brushes (308). 

(e) place the hand on the dynamo after it 
has been running and note the tempera¬ 
ture (309). 

(f) short circuited terminals will prevent 
the voltage from building up. 

(g) examine the housing for dirt or mois¬ 
ture (307). 

(h) the belt may be too loose on a belt drive 
machine (404). 

10. If the dynamo drive can be disconnected or if 

the dynamo will run free, make a test for 

motoring (310-313). 


30 STARTING AND LIGHTING TROUBLES 

11 . If any of the foregoing tests have indicated 

field trouble, test the field current (381, 382). 

12 . See that the dynamo field fuse is not burned 

out (383). 

13 . Try closing the cut-out by hand with the dy¬ 

namo running (388). 

14 . Check the adjustment of the regulating system 

(400-402). 

(a) third brush (412-419). 

(b) vibrating relay (420-433). 

(c) centrifugal systems (440-451). 

(d) other systems (460-499). 

15 . Make the following tests on the dynamo. 

(a) armature grounded (361). 

(b) armature open or short circuited (361- 
364). 

(c) field open circuited (381-384). 

(cl) field resistance high (381, 385). 

(e) field grounded or shorted (381, 386, 387) 

(f) fields reversed (381, 389). 

(g) brush position (326). 


TROUBLE FINDING CHARTS 31 

CHART 0. 

High Specific Gravity or High Charge Rate 

1. Test the output of the dynamo and check it 

against the correct current for the equipment 
being handled (301, 303). liefer to miorma- 
tion given in wiring diagram section. 

2. If the dynamo output is high follow 3; but if 

the output is normal make test 4. 

3. Test the specific gravity of the battery. If 

above 1.300, it may be due to the following 
causes. 

(a) long daylight runs or excessive over¬ 
charging (774). 

(b) acid or electrolyte added to battery 
(708). 

(c) battery overheated (759, 760). 

High output from the dynamo may be -due to 
regulation adjustment (400, 401). 

(a) third brush (414-419). 

(b) vibrating relays (426,429-431). 

(c) centrifugal regulators (443, 444, 445, 
450). 

(d) other systems (460-499). 


32 


STARTING AND LIGHTING TROUBLES 


CHART P 

Incorrect Battery Voltage or Gravity 

1. When testing the specific gravity, note the fol¬ 
lowing : 

(a) is the level of the electrolyte very low? 
(701-702). 

(b) does the liquid drawn into the hydro¬ 
meter syringe appear dirty? (707). 

(c) is one cell completely dead or much be¬ 
low the others in gravity? (751, 752). 

(d) are vent plugs loose or cracked? (756). 

(e) is the specific gravity above 1.300? (773) 

3. Crank the engine by hand and note: 

(a) does it require a great deal of cranking 
to start the engine ? 

(b) is it difficult to crank the engine, that 
is, is the engine stiff? 

4. Examine the battery for the following : 

(a) battery top wet or dirty (711, 712). 

(b) terminals corroded or dirty (714, 715). 

(c) terminal connections loose (718). 

(d) battery loose in carrier or box (730). 

(e) no air space around battery, or air space 
filled up (732). 

(f) battery cables so short that they are 
pulled tight (733). 

(g) copper wires attached at or near bat¬ 
tery terminals (742). 

(h) battery case rotted (754, 755). 

(i) terminal posts or connecting bars loose 
(757). 

(j) vloes battery temperature rise above 
100° F.? (759, 760). 


TROUBLE FINDING CHARTS 33 

5 . Examine the battery connections. 

(a) poor ground connection with one wire 
system (741). 

(b) battery leads reversed in polarity (126, 
127, 743). 

(c) is the charge unevenly divided between 
parts of double voltage battery? (658, 
744). 

6. Test the load or discharge of the battery (121). 

(a) battery capacity too small (776). 

(b) overloads of any kind. See Chart M. 

7. Test the charge rate to the battery (121). 

(a) low charge or no charge (771). See 
Chart N. 

(b) high charge rate (772, 773). See Chart 

0 . 

8. If battery has been recently repaired, any of 

the following troubles may be present. 

(a) defective sealing of jars or posts (758). 

(b) breakage or looseness of jars, posts, 
connectors, etc., (781). 

(c) separators have been allowed to dry 
(782). 

(d) separators turned with ribbed side to¬ 
ward negative plate (783). 

(e) one or more separators omitted (784). 

(f) negative plates have been exposed to 
the air (785). 

(g) positive plates have been exposed to 
the light (786). 

(h) flux has been used in lead burning (787). 


CHAPTER II 
TESTING EQUIPMENT 

1. The instruments which are most generally use¬ 
ful and with which the quickest and most accurate 
results may be obtained are the voltmeter and the 
ammeter. In some cases the two instruments are 
combined in one which is called a voltammeter. - 

The voltmeter measures the electrical pressure in 
volts or in fractions of volts and is useful in all tests 
for locating troubles which affect the voltage in the 
wires or units. 

The ammeter measures the flew cf current passing in 
a conductor, showing the rate of flow in amperes or 
in fractions of an ampere. This instrument is useful 
in locating all troubles which cause a change in the 
current flow. 

The voltammeter generally consists of a voltmeter 
provided with such combinations cf resistances and 
shunts that it may be used to measure voltage or to 
measure amperage passing through the shunts. 

Lamp bulbs through which may flow current from 
the battery on the car, or current from the shop 
lighting lines, are also useful in making certain tests. 
However, no test can be made with either form of 
test lamp that cannot be made equally well or better 
with a voltmeter or an ammeter. 

Should the workman not be provided with either 

34 








TESTING EQUIPMENT 


35 


a voltmeter or an ammeter, it will be possible to 
make about 70 percent of the tests with either form 
of test lamp or by inspection. While the results 
may not be as accurate or definite as with the meters, 
the lamp and inspection tests will generally allow 
the trouble to be located and remedied. 


TESTS MADE BY INSPECTION 

2. The following named troubles may be located 
by inspection as explained in the pages describing 
the various tests. In some cases the same trouble 
may also be located by one or more types of testing 
equipment which may serve to make the indications 
more definite or reliable. 


Causes of overload due to 
incorrect operation of 
lamps and accessories 
(216). 

Incorrect lamp focus or 
condition of the reflector 
(202-204). 

Fuses or circuit breakers 
which are open circuited 
or which contain high re¬ 
sistance (22.0-24(1). 

Troubles indicated by poor 
performance of the dyna¬ 
mo when operated as a 
motor (310-313). 

Troubles caused by dirt or 
oil in the dynamo or 
motor (307). 

Wrong brush tension (323). 

Commutator troubles of a 
mechanical nature (341- 
345). 

Loose bearings in dynamo 
or motor (306). 

Burned out field fuses (383). 

Dvnamo field magnets dead 
(381, 389). 


Loose or poorly fitted pole 
pieces in dynamo or mo¬ 
tor (300). 

Wrong brush pressure in 
governors (447). 

Cut-out troubles due to 
looseness, dirty parts, oil 
or moisture (501). 

Wires reversed at cut-out or 
dynamo (503). 

Open circuited cut-out wind¬ 
ings, either shunt or 
series (504, 505). 

Troubles indicated by spark¬ 
ing brushes (308). 

Troubles indicated by no 
cranking or slow crank¬ 
ing of engine (606, 607). 

Troubles indicated by per¬ 
formance of starting mo¬ 
tor while running free 
(609). 

Troubles in driving connec¬ 
tions, in pinion shifts and 
in overrunning clutehes 
(680-683). 


36 STARTING AND LIGHTING TROUBLES 

Tests made by inspection generally lead to conclu¬ 
sions that one or more of a general class of troubles 
may be present. It is almost always advisable to 
make further detailed tests in order to determine 
which particular fault exists, or just where it exists. 

USING VOLTMETERS AND AMMETERS 

3. In using any meter, if in doubt as to the volt¬ 
age or amperage to be measured, start with the 
highest range that the instrument provides. If the 
first test indicates that the voltage or amperage is 
less than the highest point of the next lower range, 
drop to that range and repeat the procedure. This 
is to avoid accidently burning out the meter with a 
heavy overload. 

While good meters will stand a momentary over¬ 
load of from t w o to four times their normal capacity, 
permanent connections should never be made until 
it has been ascertained that the current or voltage 
is within the instrument’s range as explained in the 
foregoing paragraph. 

4. If the meter reads backward when first con¬ 
nected, change the connections at the line or unit 
being tested, not at the meter. A reverse flow within 
the capacity of the meter will not injure it. 

5. Do not alter the cables attached to the meter 
or those that are furnished with it, as the resistance 
of these cables forms a part of the total resistance 
of the instrument and changing them may cause an 
error in the readings obtained. 

6. With the meter in the position in which it is 
to be used, the pointer should stand at zero. If it 

.stands either way from zero, the pointer or the scale 
should be adjusted, the method of adjustment de- 









TESTING EQUIPMENT 


pending op. the make and type of instrument being 
used. 

After th< pointer lias been set at zero, the meter 
may be tested for balance by tilting it in several 
ways. The- pointer should not deviate more than 
1/16 inch cither way in any position. Instruments 
generally give the best results when laid flat, 
although portable types may generally be used in 
any position that is convenient. 

The meter may be tested for sluggishness by caus¬ 
ing the pointer to swing and then noting whether it 
comes back to zero. If the movement is sluggish, 
the readings should be taken while gently tapping 
the meter case with the finger. 

7. In reading indications on the scale, it should 
be looked at from a point directly in front of the 
pointer whenever possible. If the observation is 
diagonal! v across the needle, the point apparently 
indicated on the scale may be either one side or the 
other of ,;he true reading. 

Electrical measuring instruments are delicate and 
should be given great care if they are to remain 
accurate. When riding on street cars or trains, 
carry the meter in the lap, not on the floor of the 
car. 


THE VOLTMETER 

8. The principle upon which the moving coil type 
of voltmeter operates is shown in Figure. 1. 

This is the type of instrument generally used for 
testing. 

The meter is connected by its terminals N and P 
between the points whose voltage difference is to be 
measured. The resistance R allows a small current, 


STARTING AND LIGHTING TROUBLES 



Figure 1.—Voltmeter Internal Connections. 

























TESTING EQUIPMENT 


30 


usually from 1/20 to 1/10 ampere, to flow through 
the coil C which is pivoted between the poles of the 
permanent magnet M-M. 

The magnetic field thus set up by the coil reacts 
with the field of the permanent magnet and the coil 
tends to revolve on its pivots. This tendency to turn 
is resisted by a small coiled spring (not shown) so 
that the spring is wound up until its tension balances 
the turning effort of the coil. As the coil rotates, it 
moves the pointer H across the scale 8 which is marked 
on a dial. The point on the scale at which the pointer 
comes to rest indicates the voltage acting between the 
terminals N and P. 

The voltage which will cause the pointer to travel 
ail the way across the scale; that is, the voltage which 
causes a full deflection, is dependent on the construc¬ 
tion of the entire instrument. However, the same in¬ 
strument which, in the illustration, is sh.wn with a 
scale reading from 0 to 15 volts could be used to 
measure pressures only up to 3 volts, for example, by 
allowing the current to pass through less of the 
resistance. 

9 . Such an effect would be secured as shown in 
Figure 2, which iffustrates what is known as a two 
range voltmeter. With the connections made between 
the terminals 15 and +, the instrument will be, in 
effect, the same as that shown in the foregoing illustra¬ 
tion. If now the connections are made between 
terminals 3 and +, there will be a greater flow through 
the meter because of the reduced resistance, and for a 
given voltage the movement of the coil and pointer will 
be greater and 3 volts will now cause a full deflection. 
With this connection, the lower scale, reading from 
0 to 3, is used in taking the reading. 


STARTING AND LIGHTING TROUBLES 






























TESTING EQUIPMENT 


41 


Voltmeters are also made to give a full scale reading 
under a pressure of 1/10 (0.1) volt. Such an instru¬ 
ment, or the range of this value, is then known as a 
100 millivolt meter, a millivolt being equal to 1/1000 
volt. Meters reading above 15 volts are also made 
but are not generally used in automobile work, inas¬ 
much as the present electrical systems generally use 
operating voltages of either 6 or 12. 

VOLTMETER CONNECTIONS 

10. A voltmeter is used only in measuring pres¬ 
sure of the electric current. Because there are dif¬ 
ferences in pressure or voltage only between separate 
points in a circuit, the voltmeter is always connected so 
that a difference in pressure will be measured. 

To measure the difference in pressure acting between 
two points in a circuit the voltmeter is connected as 
shown in Figure 3, the connection at A measuring the 
voltage between points on opposite sides of a circuit; 
that at B measuring the voltage at the terminals of 
a dynamo; while that at C would measure the volt¬ 
age of a storage battery. 

As a general rule and unless otherwise directed in 
certain tests, the voltmeter should be connected be¬ 
tween the positive and negative sides of a circuit. 

VOLTMETER TESTS 

11. A voltmeter having a range of 0 to 15 will 
be found sufficient for most of the tests, although a 
meter reading up to 25 or 30 volts may be used. With 
the higher range the divisions on the scale will not be 
as large and the measurement will not be as accurate. 

The 1/10 volt range is called for only in making 
tests for a short circuited armature winding. 









Figure 3.—Testing Connections for Voltmeter. 


































TESTING EQUIPMENT 


43 


12. The 3 volt range is used in the following 
tests: 

Open circuited armature winding. 

Individual battery cells. 

Resistance of lines or circuits. 

13. The 15 volt range is used in making the fol¬ 
lowing tests: 

Short circuits, grounds, open circuits or high resist¬ 
ance in wiring, lamps or switches. 

Fuse or circuit breaker trouble. 

Dynamo vcltage test. 

Shorts in dynamo housing. 

Poor brush contact. 

Open circuit or high resistance in brush circuit. 
Grounded armature. 

Burned out field fuse. 

Open circuited field winding. 

High resistance in field circuit. 

Shorted or grounded fields. 

Constant voltage regulation faults. 

Vibrating relay open or short circuits. 

Reversed relay connections. 

Constant speed governors. 

Open or shorted regulator resistance. 

Cut-out connections and minor cut-out troubles. 
Open circuits in cut-out windings. 

Adjustment for cut-cut closing. 

Starting motor power test. 

Battery vcltage. 

Tests for line polarity. 

Tests for open circuits. 

Tests for excessive resistance. 

Tests for short circuits. 

Test for accidental grounds. 


44 


STARTING AND LIGHTING TROUBLES 


THE AMMETER 

14 . The principle and internal construction of 
the ammeter are the same as that of the voltmeter 
already described. By the use of shunts, through 
which most of the current passes, the meter is adapted 
to measure the flow through a circuit rather than the 
pressure. 



By referring to Figure 4 it will be seen that cur¬ 
rent passing from A to B will divide and flow through 
the paths S and M between the terminals. Path S is 
of large size and consequently of low resistance. 
Therefore, the greater part of the current will flow 
through this low resistance path. Path M is of small 
size and high resistance and but very little flow of 
current will take place through it. 

The total flow of current will pass through S and M 
under all conditions, but the division will depend on 













TESTING EQUIPMENT 


45 


the inverse ratio of their resistances, which ratio re¬ 
mains constant. Therefore, the flow through M will 
always be in proportion to the flow through 8 and to 
the total flow. That is, with an increase of total flow, 
there will be a corresponding increase through M. 

The resistance M, in this case, represents the volt¬ 
meter, while S represents a carefully calibrated shunt 
which may be carried inside the voltmeter case, the 



meter then being called an ammeter, or the shunt may 
be external and connected to the voltmeter by leads. 

15 . An ammeter with external shunt is shown in 
Figure 5. The resistance of the shunt S is so low 
that it carries the greater part of the current and 
but a very small flow takes place through the meter. 
This flow is kept within the meter’s range or capacity. 
The indication :>f the pointer on the scale is then read 







4<> STARTING AND LIGHTING TROUBLES 

directly as amperes flowing in the circuit with which 
the shunt is in series. 

By using shunts with various resistances or capaci¬ 
ties, the capacity of the instrument as an ammeter may 
be suited to the work in hand. Shunts for automobile 
work are generally of ranges allowing a full scale 
deflection for 2or 3 amperes, 25 cr 30 amperes and 
250 to 300 amperes. Each range is suited for certain 
classes of work. 

Instruments having several self contained shunts are 
provided with additional terminals for making con¬ 
nections while measuring the various amperages. 

16. An ammeter, or its shunt, should be con¬ 
nected in series with the circuit whose amperage or 
current flow is to be measured. That is, the circuit 
should be opened at some point and the ammeter or 
the shunt placed between the points disconnected. 

An ammeter is never used for testing a storage 
battery, as the heavy flow would burn out the windings. 

AMMETER TESTS 

17. An ammeter having a range of 0 to 25 or 30 
will be found sufficient in capacity for tests on the 
lighting, ignition or charging equipment. A meter 
having a higher range, from 250 to 500, is required 
for most of the tests on starting equipment because 
of the heavy flow of current encountered in this class 
of work. The higher range is also safer to use in 
testing for short circuits or grounds because if these 
faults are very bad, a high flow of current may pass 
through them. 

18. A range up to 25 or 30 amperes will make 
the following tests: 

Open circuits or high resistance in wiring, lamps 
or switches. 


TESTING EQUIPMENT 


4 7 


Overloads in the lighting system which are not 
caused by shorts or grounds. 

Fuse or circuit breaker trouble. 

Dynamo output tests. 

Test of running dynamo as a motor. 

Dynamo brush contact trouble or open circuit. 
Grounded armature. 

Open or short circuited armature. 

Dynamo field current test. 

Field fuse burned out. 

Open circuit or high resistance in field windings. 
Shorts or grounds in dynamo fields. 

Amperage control regulation. 

Vibrating relay open or short circuits. 

Constant speed governors. 

Open or shorted regulator resistance. 

Cut-out connections and minor troubles. 

Open circuits in cut-out windings. 

Adjustment for cut-out opening. 

Trouble in manual cut-outs. 

Tests for open circuits. 

Tests for high resistance. 

19. A range up to 250 or 300 amperes will be suit¬ 
able for the following tests: 

Short circuits or grounds in wiring, lamps and 
switches. 

Starting motor brush troubles. 

Shorts or grounds in motor fields. 

Test with starting motor running free. 

Starting motor power test. 

Starting switch troubles. 

General tests for short circuits. 

General tests for accidental grounds. 


48 


STARTING AND LIGHTING TROUBLES 


LOW VOLTAGE TEST LAMP 

20. A large number of tests may be made with a 
lamp bulb of the same voltage as that used for light¬ 
ing the car, or of a voltage equal to twice the number 
of cells in the battery. The bulb is inserted in a 
socket to which two leads are fastened so that the 
outfit is as shown in Figure 6. 



Figure 6.—Test Lamp For Use With Battery Current. 

21. In case the car’s electrical equipment is of 
the double voltage type, using a higher voltage for 
starting than for lighting and charging; the lamp 
bulb will probably be burned out should it be used 
in the starting circuit. In this case, two or four such 
bulbs may be used in series, the number depending on 
the number of times the starting voltage is greater 
than the lighting voltage. It would also be possible 
to use one bulb of a voltage the same as that used for 
starting. 

22. If the battery on the car is sufficiently 
charged to light the lamp, the tester may be con¬ 
nected in series with the battery at the battery 
terminals, or it may be used between any two points 
in the equipment as directed in the detailed explana¬ 
tions for testing. 

23. If the car’s battery is discharged, such a lamp 

tester would have to be connected on outside batterv 

«’ 



TESTING EQUIPMENT 


49 


and in such a case it would probably be more con¬ 
venient to use a lamp connected with the shop light¬ 
ing system and which will be described later. 

LOW VOLTAGE LAMP TESTS 

24. The following tests can be made with the 
low voltage lamp, but cannot be made, or at least 
will not be so well made, with a high voltage lamp 
connected with the shop lighting lines: 

High resistance in wiring, lamps or switches. 

Overloads in lighting system. 

High resistance in fuses or circuit breakers. 

Test of dynamo output or voltage. 

Test of poor brush contact. 

High resistance in field circuit. 

25. The following tests can be made with either 
the low voltage lamp just described or with the high 
voltage lamp to be described next: 

Shorts, grounds or open circuits in wiring, lamps, 
switches, fuses or circuit breakers. 

Burned out field fuse. 

Open or short circuited relays. 

Open or short circuited regulating resistance. 

Tests for open circuits. 

Tests for high resistance. 

Open circuit to brushes. 

Grounded armatures. 

Open circuited, grounded or shorted field windings. 

Tests for short circuits. 

Tests for accidental grounds. 

HIGH VOLTAGE TEST LAMP 

, " ... • I 

26. A tester may be secured by cutting one side 
of the drop cord for a shop light and using the two 
free ends thus obtained as the test points. 


50 


STARTING AND LIGHTING TROUBLES 


An outfit operating on the same principle, but made 
in a more workmanlike manner, may be constructed 
as shown in Figure 7. The complete tester, with its 
leads and a bulb of low candlepower and preferably 
with a carbon filament, may then be screwed into any 
live socket. The low candlepower lamp should be 
used because of the lower amperage passing through 
the circuits, this small flow being less liable to cause 



Figure 7.—Test Lamp Attached to Shop Lighting System. 

relays, coils and circuit breakers to operate during 
tests. 

27. This form of tester may be used for locating 
open circuits, short circuits or grounds. It is not 
suited for locating points of high resistance because 
the high voltage will pass through resistances with 
ease which would almost prevent current flow at the 
low pressure of the battery or dynamo. 















TESTING EQUIPMENT 


51 


The high voltage lamp is especially useful in locat¬ 
ing slight shorts or grounds which, with the low bat¬ 
tery voltage, allow but a small leak, but which are 
immediately apparent under the high voltage test. 

A list of the tests which may be made with this 
tester has been given under the head of “Low Voltage 
Test Lamp.” 







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52 STARTING AND LIGHTING TROUBLES 


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CHAPTER III 


CIRCUIT TESTING 


101. The tests explained in this chapter are of a 
general nature and may be applied, with certain 
variations, to the location of all forms of electrical 
trouble. They are applied in detail, with explanations 
of the meanings of various results, in following 
chapters on the several units which make up the elec¬ 
trical equipment of the car. 

The methods of making these tests and the principles 
involved should be thoroughly understood, because 
such an understanding will make all other work com¬ 
paratively easy of performance and will also allow 
the workman to devise many special applications of 
his own in meeting peculiar conditions which may be 
encountered. 

102. These circuit tests include the following: 


Open Circuits 


High Resistance 


In which it is impossible for tin 1 
current to return to the nega¬ 
tive side of the source after 
leaving the positive; therefore, 
.conditions under which there 
is no current how. 

In which some portion or point 
in the circuit is of such high 
electrical resistance that the 
current flow in amperes is re¬ 
duced below a value at which 
proj~?r operation takes place. 

57 


STARTING AND LIGHTING TROUBLES 


58 


Short Circuit 


Ground 


Load Test 


Voltage Loss Test 


Resistance Test 


Polarity Tests 


In which current returns to the 
negative side of the source 
through a path other than that 
through the current consum¬ 
ing devices of the car’s equip¬ 
ment. This short path is gen¬ 
erally of low resistance and 
allows a high amperage to 
pass. 

A short circuit taking place 
through the metal of the car 
parts or of the electrical 
equipment units, not through 
the proper conductors. 

A test to determine whether or 
not overloads exist, that is, 
wheth any part of the equip¬ 
ment is drawing an excessive 
flow not due to short circuits 
or grounds. 

A test to determine the actual 
electrical pressure at the cur¬ 
rent consuming devices in 
proportion to the pressure at 
the source. 

To determine the electrical re¬ 
sistance of any current con¬ 
ducting path or of any circuit. 

To determine the direction in 
which the electric current 
flows through a circuit, or 
whether a certain terminal or 
line is of positive or negative 





CIRCUIT TESTING 


59 


polarity. Also to determine 
the polarity of magnets and 
motor or dynamo fields. 

OPEN CIRCUIT TESTS 

103. Testing in Series.— Any testing instrument, 
voltmeter, ammeter or lamp, may be inserted in series 
with the circuit to be tested by opening a joint and 
connecting the instrument between the two points 




B 


Figure 8.—Open Circuit Test With Series Connection of 

Tester. 

separated as shown in Figure 8. A voltmeter, am¬ 
meter or low voltage lamp is connected as shown at 
A, a high voltage lamp as shown at B. The connec¬ 
tion at A is used when a storage battery, or a dynamo 
in operation, is in the circuit, as it is necessary for 



















GO STARTING AND LIGHTING TROUBLES 

either battery or dynamo to provide electricity to 
operate the tester. 

If the battery or dynamo cannot be depended upon 
for current, the high voltage lamp may be used from 
the shop lighting system. 

if the circuit is complete and current passing, 
the voltmeter or ammeter pointer will move from zero, 
or the test lamp will light. 

If the circuit is open so that current cannot pass, 
the pointer of the meter will remain at zero or the 
hi nip will remain out. 

This form of open circuit test requires that some 
connection be opened. It is not always convenient to 
do this and in such a case an open circuit test may be 
made with the tester in parallel. 

104. Testing- in Parallel.—To illustrate the prin¬ 
ciple of this method, Figure 9 may be referred to. It 
is assumed for illustration that a coil is to be tested 
for an open circuit, although the test would be made 
in the same manner between any two terminals of any 
electrical device. 

As at the left, the circuit through the coil is com¬ 
plete. In most cases, the greater part of the current 
How will pass through the coil and but very little 
through the meter or lamp when connected as shown 
across the terminals. If the unit being tested is of 
high resistance, such as an ignition coil, there may 
lie a considerable flow through the tester and this 
condition will also be considered. 

If the circuit through the coil or other unit is open 
as at the right, there will be no flow through the unit, 
and all the current passing in the circuit will then 
flow through the tester. 

Therefore, with such a parallel connection, if a full 




CIRCUIT TESTING 


61 


current flow is indicated by the meter or lamp, it 
shows that the unit is open circuited. If little or no 
flow is indicated, it shows that the circuit is not open. 

The voltmeter or low voltage lamp is more satis¬ 
factory for this test than the ammeter because the 
ammeter is of such low resistance in itself that it is 
quite possible for most of the flow to pass through 
the meter regardless of the condition inside the unit 
being tested. This makes the difference in ammeter 




Figure 9.—Open Circuit Test With Parallel Connection of 

Tester. 


reading very slight between the two conditions, espe¬ 
cially in case the internal resistance of the unit is 
normally high. 

The voltmeter indication will be almost as high as 
that of the source (battery or dynamo) in case the 
unit is open circuited. If the voltage indicated is 










62 


STARTING AND LIGHTING TROUBLES 


zero, or but little above zero, it indicates that there is 
no open circuit. 

If the test lamp burns brightly, it indicates that 
the unit is epen circuited. If the lamp remains out 
or burns very dimly, it indicates that no open circuit 
exists. 

The resistance of either the voltmeter or test lamp 
is so high that they allow a very small flow through 
themselves and the indications are therefore more posi¬ 
tive than with the ammeter. 


105. OPEN CIRCUIT TESTS 


INSTRUMENT 

USED 


SERIES TEST INDI¬ 
CATIONS 


PARALLEL TEST INDICATIONS 



OPEN 

CIRCUIT 

NO 

TROUBLE 

OPEN CIRCUR 

NO TROUBLE 

VOLTMETER 

Zero 

Full 

voltage 

Full voltage 

Zero or very 
low voltage 

AMMETER 

Zero 

Any 

reading 



LOW VOLT¬ 
AGE LAMP 

Out 

Lighted 

Burns 

brightly 

Out or dim 

HIGH VOLT¬ 
AGE LAMP 

Out 

Lighted 




HIGH RESISTANCE TESTS 

106. A point of excessively high resistance re¬ 
duces the flow through a circuit but does not stop it 
entirely. For this reason, an ammeter which directly 
measures the flow, is the most satisfactory instrument 
for this work provided the normal flow is known. The 
normal flow to any current consuming device may be 
quite closely ca 1 ciliated by reference to several of the 
tables given in Chapter XT. With a normal reading 

































CIRCUIT TESTING 


63 


as shown at the top in Figure 10, a high resistance 
would cause a drop as shown at the bottom. 




The low voltage test lamp may be used in some 
cases, but a resistance great enough to prevent proper 
battery charging or to prevent proper operation of the 


















64 


STARTING AND LIGHTING TROUBLES 


starting motor, might not be high enough to prevent 
the small flow required by the lamp and its indications 
would cause a drop as shown at the bottom. 

The voltmeter can also be used in some cases be¬ 
cause the voltage between two points is affected by 
the resistance in most cases. 

The high voltage test lamp is not satisfactory for 
locating high resistances because the pressure of the 
shop lighting system causes a flow great enough to 
light the lamp even with considerable resistance in 
circuit. 

107. The operation of the lamps, horn and starter 
on the car forms a valuable indication of the presence 
of high resistances. If the lamps burn dimly, if the 
horn does not blow loudlv or if the starter cranks 

4/ 

slowly while it is known that the battery is well 
charged, it is quite possible that the trouble is caused 
by high resistance in the lines to the units thus 
affected. 

108. Ammeter or Lamp Test. —An ammeter or a 
low voltage test lamp may be connected as shown in 
Figure 11 by opening a connection at either end of the 
line suspected of containing the resistance. 

The switch for the unit at the end of the line should 
be closed and the amperage passing should be noted 
on the meter scale. 

If a point of high resistance, such as at Ii, exists 
between the battery or dynamo B, and the current 
consuming device C, the amperage will be below 
normal. 

If the test lamp is used and the amperage is very 
low, the lamp will burn brightly, otherwise it will 
burn dimly. As mentioned, the test lamp is not gen- 
erally satisfactory when used in this way. 



CIRCUIT TESTING 


£5 


109. Voltmeter Test. —With a voltmeter con¬ 
nected to two points between which it is suspected that 
a high resistance exists, such as the two terminals of 
R in Figure 12, the reading on the voltmeter will 
be determined by the ratio between the resistances of 
R and the meter. 



If the voltmeter indicates a voltage much below that 
of the source (battery or dynamo) it shows that the 
resistance of R is not high, that is, no trouble of the 
kind considered is present. The reading in this case 
may be almost zero. 

If, however, the voltmeter shows a voltage almost 
as high as that of the battery or dynamo, it indicates 



















66 


STARTING AND LIGHTING TROUBLES 


that the resistance of R is very high. If it is known 
that R should have a low resistance, such a high read¬ 
ing of the voltmeter indicates trouble of the kind con¬ 
sidered here. If it is known that R has a compara¬ 
tively high resistance, then this test is not of great 
value. 



Figure 12.—High Resistance Test With Voltmeter. 


110 . HIGH RESISTANCE TESTS 


INSTRUMENT 

USED 

INDICATION 

CONNECTION 

MADE 


HIGH 

RESISTANCE 

NO 

TROUBLE 


AMMETER 

Below 

normal 

Normal 

amperage 

In series 

LOW VOLTAGE LAMP 

Out or dim 

Burns 

brightly 

In series 

VOLTMETER 

High volt¬ 
age but 
below 
battery 

Zero or 
very low 
voltage 

In parallel 


























CIRCUIT TESTING 


67 


SHORT CIRCUIT TESTS 

111. A short circuit allows a greater flow of cur¬ 
rent than should normally take place and this flow of 
current is between two conductors which should be 
insulated from each other, neither conductor being a 
metal part of the car or equipment. 

Short circuits may be located by either of two 
methods: First, by testing for an electrical connection 
between two normally insulated conductors; second. 



by noting the excessive flow from the current source as 
long as the short circuit exists. 

112. Testing Conductors. —The principle of the 
first method is illustrated in Figure 13. Any form of 
circuit tester, T, connected to an external source of 
current may be used. That is, either a high voltage 
test lamp, a low voltage lamp connected to an outside 














G8 starting and lighting troubles 

battery, an ammeter connected to one dry cell or a 
voltmeter connected to an outside battery may be used. 

An ammeter should not be used in locating short 
circuits unless it is connected with one dry cell, be¬ 
cause connecting this instrument to a storage battery 
or to the shop lighting system would allow a flow of 
current through it which would burn out the meter 
coil and shunt. A single dry cell will not give a flow 
above 15 or 20 amperes. 

The high voltage test lamp is most satisfactory for 
this method of testing because its pressure will send 
a current through any form of short that will affect 
the car’s equipment. 

If there is no electrical connection between the two 
conductors, as at A in the illustration, the tester will 
indicate no flow of current. 

If there is a short circuit, as shown at B, then the 
circuit tester will indicate a pressure or flow of current. 

113. The practical application of this principle 
is shown in Figure 14. A short circuit is supposed to 
exist between the two lines M-L and N-K. With 
each end of the suspected lines disconnected as shown, 
the tester T is placed on one end of each line. The 
terminal connections are opened at M and A, the lamp 
bulb is removed from L and the horn wire is discon¬ 
nected at K. 

If, under these conditions, there is a current flow, 
the tester will indicate the fact. If there is no indi¬ 
cation, the lines are properly insulated. 

If the lines were not disconnected at both ends 
there might have been a flow between M and N through 
the switch and there would have been a flow through 
the lamp bulb of L to the horn ground and to K. 

Neither of these would have been a short circuit, vet 

■ •/ 






CIRCUIT TESTING 


69 
















TO 


STARTING AND LIGHTING TROUBLES 


they would have allowed the tester to indicate a 
short. 


114. SHORT CIRCUIT TESTS 


INSTRUMENT USED 

AS TESTER 

CURRENT 

SOURCE 

SHORT 

CIRCUIT 

NO 

TROUBLE 

HIGH VOLTAGE LAMP 

Shop light¬ 
ing lines 

Lamp 

lights 

Lamp out 

LOW VOLTAGE LAMP 

Storage 

battery 

Lamp 

lights 

Lamp out 

V OLTMETER 

Storage 

battery 

Any read¬ 
ing 

Zero 

AMMETER 

One dry 
cell 

Any read¬ 
ing 

Zero 


GROUND TESTS 


115. A ground is a short circuit and acts like a 
short circuit. It is, however, looked for between a 
normally insulated conductor or electrical unit and 
the metal of the car. 

Grounds, like short circuits, may be located either by 
testing between the conductor suspected and the metal 
of the car, or by noting the excessive flow from the 
battery as long as the ground exists. 

In locating accidental grounds it is usually neces- 
sary to open all intentional grounds by removing lamp 
bulbs, disconnecting the horn and ignition, etc. 
Otherwise it is possible that these intentional grounds 
may give a misleading indication. 

116. Test Between Conductor and Ground.—The 
principle of the first method is shown in Figure 15. 
The same remarks given under the heading of “Testing 
Conductors” for short circuits (Section 112) apply 
also to this method of testing for grounds. 


































CIRCUIT TESTING 


71 


The high voltage test lamp is most satisfactory, 
while a voltmeter or a low voltage lamp attached to 
an outside battery will give good results. An ammeter 
should not be used unless connected to one dry cell 



and under this condition the voltage of the single 
cell is so low that slight grounds, such as caused by 
dirt, oil or moisture, may not be indicated. 

If there is no electrical connection between the sus¬ 
pected conductor and the metal of the car, as at A. 
there will be no indication of current or pressure. 

























72 


STARTING AND LIGHTING TROUBLES 



Figure 16.—Testing for Grounded Wires. 












CIRCUIT TESTING 


73 


If a ground exists, as at B, there will be an indicar 
tion cf current flow through the tester. 

117. The practical application of this principle in 
locating grounds is shown in Figure 15. Each end of 
the suspected conductor is disconnected as for locating 
shorts. The tester is then connected between one end 
of the line and the metal of the car as shown. 

A ground, such as shown at G on the line M-L, will 
then allow the tester to indicate the fact. The only 



Figure 17.—Test for Short or Ground With Tester in Series. 

difference between this test and that for shorts is that 
the tester is connected on one side to the metal of the 
car in looking for grounds, while for shorts the tester 
is connected to two conductors. The table of short 
circuit tests (114) applies in full to this method of 
locating grounds. 

SHORT CIRCUIT OR GROUND TEST 

118. The principle of the second method of locat¬ 
ing either short circuits or grounds is shown in 
Figure 17. Any form of tester; voltmeter, ammeter, 















74 STARTING AND LIGHTING TROUBLES 

low voltage lamp or high voltage lamp; is connected as 
shown at T by removing the cable from one terminal 
of the battery and connecting the tester between the 
cable end and the battery terminal. 

If there is an electrical connection between the posi¬ 
tive and negative sides of the battery, as would be 





Figure 18. —Application of Series Test for Short or Ground. 


provided through the line and switch when closed, the 
tester will indicate a flow of current or pressure. If 
this flow is caused by an accidental connection it will 
stop when the accidental connection, represented by a 
short or ground, is removed. In the illustration, a 
flow would be caused by the switch being accidentally 
closed. 

As long as the switch remains closed, there will be 


















CIRCUIT TESTING 


75 


a flow of current shown by the tester, but as soon as 
the trouble is located and the switch opened, the tester 
will indicate the fact by showing no flow of current. 

119. The application of this method in practice 
is shown in Figure 18. A tester is connected in series 
with the battery as shown between the battery terminal 
B and the cable end C. 

Should a short circuit, which in this case also 
causes a ground exist, as at S, the tester will show a 
current flow. When 8 is removed there will be no 
further flow of current from the battery and the tester 
will indicate this fact. 


120. SHORT CIRCUIT OR GROUND TEST 


INSTRUMENT USED 

AS TESTER 

CONNECTION 

MADE 

SHORT OR 

GROUND 

NO 

TROUBLE 

HIGH VOLTAGE LAMP 

Series with 
battery 

Lamp lights 

Lamp out 

LOW VOLTAGE LAMP 

Series with 
battery 

Lamp lights 

Lamp out 

VOLTMETER 

Series with 
battery 

Any read¬ 
ing 

Zero 

AMMETER NOT SAFE 
TO USE 

Series with 
battery 

Any read¬ 
ing 

Zero 


LOAD TEST 

121. Any circuit or any electrical unit may draAV 
an abnormally high amperage, called an overload, and 
yet this trouble may not be caused by either a short 
circuit or a ground. 

Such troubles are caused by faults in the starting 
motor or drive connections, by the use of too many 
lamps, of lamps of too high candlepower or by wrong 
use of the lamps. It might also be caused by the addi- 



























76 


STARTING AND LIGHTING TROUBLES 


tion of too many accessories or by wrong connections. 

The load for any part of the equipment may be 
found upon connecting an ammeter in series with the 
battery by disconnecting one of the cables and insert¬ 
ing the meter between the cable and the battery ter¬ 
minal as shown in Figure 19. Then, by turning on 
the switches for the equipment to be tested, the 
amperage may be found. 

For tests of the lighting and charging system and 
of accessories, a meter reading up to 25 or 30 amperes 



should be used. For testing the starter a meter should 
read up to 300 or more amperes. 

The normal load for lamps and horns may be found 
by using Table IV. 

RESISTANCE TEST 

122. The resistance of any conductor or of any 
electrical unit may be calculated by measuring the 
drop of voltage between the two ends of the conductor 
or between the terminals of the unit. The test requires 
the use of a voltmeter and an ammeter. 

The connections used in measuring the resistance 






CIRCUIT TESTING 


77 


of a conductor are shown in Figure 20. Those used 
in measuring the resistance of any unit, such as a 
motor, are shown in Figure 21. By tracing the con¬ 
nections, it will be seen that the principle is the same 
in either case. 

A source of current S, which may be either a dynamo 
or battery, is connected to the two ends of the part 



Figure 20.—Measuring Resistance of Conductor. 


whose resistance is to be measured, R. In series with 
the source is connected the ammeter and across the 
two terminals C and D of the unit is connected a 
voltmeter so that simultaneous readings may be taken 
on both meters. 

The current flow is measured by the ammeter and 










78 


STARTING AND LIGHTING TROUBLES 



Figure 21 .—Measuring Resistance of Part of Equipment. 

























CIRCUIT TESTING 


79 


the voltage is measured by the voltmeter. The num¬ 
ber of volts divided by the number of amperes gives 
the resistance in number of ohms or in fractions of an 
ohm. 

It is advisable to test the resistance with two or 
more voltages, then to take the average of the results. 
This voltage change may be made with a battery by 
connections made across three cells, then two cells, 
then one cell. 

123. By knowing the resistance of any unit many 
useful comparisons may be made. The resistance of 
a good field coil may be compared with one thought 
defective and many similar problems may be easily 
solved. 

124. The approximate length of a winding may 
be found, first by finding its resistance in ohms, then 
by measuring the wire gage size and dividing the 
total resistance by the resistance per foot as given in 
Table I. The result will be the length of the winding 
in feet. Such tests should be made with accurate in¬ 
struments, with secure connections and with the great¬ 
est care in order to secure fairly accurate results. 

125. The voltage loss in a line for the amperage 
flowing is simply the reading given by the voltmeter 
in this test. This loss is important, especially in the 
starting circuit. 


POLARITY TESTS 

126. Current Polarity.—The direction of flow of 
a current may be determined with a voltmeter. One 
of the terminals of the meter is marked “ + ” or “—” 
and the other terminal is sometimes', although not al¬ 
ways, marked with the sign of opposite polarity. 


80 


STARTING AND LIGHTING TROUBLES 


If a positive wire is connected to the positive ter¬ 
minal of the meter and the negative wire to the other 
terminal, the pointer will move across the scale in the 
direction of the numbering. If the wire connected to 
the voltmeter terminal is of a polarity opposite to the 
sign of the terminal, the meter will read backward. 

127. If two wires of opposite polarity are dipped 
into water to which has been added a small quantity 
of any acid or salt, the negative wire will cause a 
large quantity of bubbles to rise from it, while the 



Figure 22.—Testing Polarity of Conductors. 

amount of bubbles from the positive will be much 
smaller. This is shown in Figure 22. 

128. Magnetic Polarity. —The polarity of any 
magnet, either of the permanent form or an electro¬ 
magnet, may be determined with a pocket, or mariner ’s 
compass. 

The north or positive end of the compass needle 
points to the earth’s North pole as in Figure 23. 

The positive end of the compass needle will be at¬ 
tracted to the negative pole of a magnet, while the 
negative, or South pointing, end of the needle will 
be attracted to the positive end of a magnet. 














CIRCUIT TESTING 


81 

In moving a compass from one pole to another of a 
magnet, the compass should be taken far enough away 
during the change to be well outside the magnetic field, 
otherwise the magnetism of the needle may be reversed 
and cause its indications to be directly opposite the 
truth. 



129. If the direction of current flow around an 
electromagnet is known or can be determined, the re¬ 
sulting polarity of the core may be found from the 
following rule. 

If the current flows around the core in a clockwise or 











82 


STARTING AND LIGHTING TROUBLES 


right hand direction, the end being looked at is nega¬ 
tive ; if the current flows anti-clockwise, or left handed, 
the end being looked at is positive. This is shown in 
Figure 24. 



Figure 24.—Principle of the Electro-Magnet. 













CHAPTER IV 


WIRING TROUBLES 

150. Short Circuit.—Current from the positive 
side of the current source (battery or dynamo) returns 
to the negative without passing through the proper 
current consuming devices. 

151. Ground.—A short circuit that passes through 
the metal of the car or of parts of its equipment. 

152. Open Circuit.—The current path from the 
current source (battery or dynamo) is not completed 
from the positive side, to and through the current 
consuming devices and back to the negative side of 
the source. 

153. High Resistance.—The path through which 
the current passes offers a resistance at some point 
which is so great as to prevent the necessary flow 
or amperage of current. 

154. Wrong Connections.—Any wires or con¬ 
ductors connected to points at which they should not 
be attached may make the tests useless because of 
wrong conclusions that may be drawn. 

155. Tests may be made with any of the equip¬ 
ment shown in the following table: 




STARTING AND LIGHTING TROUBLES 


S4 


TESTS OF WIRING 


TESTING EQUIPMENT 
AND CONNECTIONS 

CONDITIONS OF 

TEST 

INDICATIONS OF 

TROUBLE 

Lamp bulb of car 
voltage in series 
with battery 
or 

Ammeter in series 
with battery 
or 

Voltmeter in series 
with battery 

Ml lighting, ig¬ 
nition, starter 
and accessory 
switches 
“OFF.” 

If lamp lights or me¬ 
ter shows current 
flow or voltage it 
indicates a short 
circuit or ground. 

Lighting, igni¬ 
tion, starter 
and accessory 
switches 
turned “ON,” 
one at a time. 

Trouble is indi¬ 
cated in cir¬ 
cuit turned on; 
or, if present 
regardless of 
switches on, 
trouble is in 
main lines 
from battery 
to switches. 

If lamp remains out 
or meter shows no 
current flow or 
voltage, it indi¬ 
cates an open cir¬ 
cuit in lines for 
units whose 
switches are on. 

If lamp burns dimly 
or ammeter shows 
low amperage it 
indicates high re¬ 
sistance. Voltme¬ 
ter would show 
battery voltage in 
spite of high re¬ 
sistance. 


NOTE—The starter switch should not be closed with 
an ammeter in series unless the meter has a range up 
to 250 amperes. 

SHORT CIRCUITS OR GROUNDS 

156. Short circuits or grounds are located by 
opening the connections leading from the current 
source to the consuming devices, continuing until an 
opened connection locates the trouble. 

Tests may be made with any of the equipment 
shown in the table on page 87. Refer also to sections 
111 to 120. 













WIRING TROUBLES 


85 


Conditions of Test. —Remove the bulbs from all 
lamps. Disconnect the horn ground or the horn itself. 
Disconnect all ignition and accessory grounds or dis¬ 
connect these parts themselves. Close all lighting, 
ignition and accessory switches and keep the horn 
button pressed during the test. 

157. Testing Method. —For low voltage test lamp, 
ammeter or voltmeter refer to Figure 25. Follow the 
wiring leading away from the battery on the un¬ 
grounded side until a joint, C, is reached at which 
the lines separate. Temporarily open the joint of 
each branch line, C-D, C-E and C-F. 

If none of these open connections stop the current 
flow, as shown by the lamp or meter, it indicates that 
the trouble is between the battery and the joint; 
that is, in the main battery line, A-C, up to this point. 

If some one open connection stops the current flow, 
it indicates that the short or ground is in the line 
then disconnected from the battery lead, or in the 
part of the equipment then disconnected. 

The line containing the trouble should then be fol¬ 
lowed (according to the wiring diagram) until a 
second connection is reached, such as at E, and this 
connection should be opened as was the first one. 

If this open connection does not stop the current 
flow, as shown by the test lamp or meter, it indicates 
that the trouble lies between this opened connection 
and the joint first inspected, in the line C-E, or else 
in some of the equipment carried on that line. 

If the opened connection stops the current flow, itr 
indicates that the ground or short is farther along in 
the line then disconnected and that line should be 
followed to its next point of opening, G or II. 


SG 


STARTING AND LIGHTING TROUBLES 



Figure 25.—Testing: Complete Equipment for Short Circuit or Ground. 













































WIRING TROUBLES 


87 


The test should be continued in this way ui>,d with 
two consecutive points opened; the last one opened 
allows the current flow to continue, while the preced¬ 
ing one opened causes the current flow to stop. The 
short or ground then lies between these points, either 
in the wiring or in parts of the equipment. 


TESTING EQUIPMENT 


EQUIPMENT USED 
IN TEST 

INDICATION WHEN 
POINT OF TROUBLE 
HAS BEEN PASSED 

CURRENT WILL 

FLOW'. 

INDICATION IF 

POINT OF TROUBLE 

HAS NOT BEEN 

REACHED 

NO CURRENT WILL 

FLOW. 

Lamp bulb (car 

Test lamp will 

Test lamp will go 

voltage) in 

light with con- 

out with con- 

series with 
battery. 

nection opened. 

nection opened. 

Ammeter in se- 

Meter show's cur- 

Meter shows no 

ries with bat- 

rent iiow with 

current flow 

tery. 

connection 

with connection 


opened. 

opened. 

Voltmeter in se- 

Meter shows bat- 

Meter shows no 

ries with bat- 

tery voltage 

voltage with 

tery. 

with connection 

connection 


opened. 

opened. 

Test lamp from 

Test lamp will 

Test lamp will go 

shop lighting 

light w r ith con- 

out with con- 

system. 

nection opened. 

nection opened. 


158. Testing' Method.—For test lamp attached to 
shop lighting system refer to Figure 26. If the car 
wiring is of the ground return type, remove the un¬ 
grounded cable at the battery or as near the battery 
as possible and attach one end of the test line to this 
cable as at A. Attach the other end of the test line 
to the terminal from which the cable was removed 











88 STARTING AND LIGHTING TROUBLES 

which will allow the lamp to light because of the 
short circuit or ground that exists. 

If the car wiring is of the insulated return type, 



Figure 26.—Testing for Short or Ground With Shop Lighting 

Current. 

remove both battery cables at the battery or as near 
the battery as possible. Attach one end of the test 
line to one of the battery cables and attach the other 
end of the test line to the remaining battery cable 
as at B. 












WIRING TROUBLES 


89 


Proceed with the test by opening successive con 
nections leading away from the battery on the side 
of the circuit that leads to the switches and equipment 
units, the indications then being the same as in the 
test while using the low voltage lamp, the ammeter 
or the voltmeter. 

159. CAUSE AND REMEDIES. SHORTS AND GROUNDS , 


CAUSE 

REMEDY 

Dirt, oil or moisture between 
terminals. 

Loose terminal connections 
touching metal. 

Loose wire strands at ter¬ 
minals. 

Exposed terminal connec¬ 
tions should be clean, 
tightly made, covered with 
tape and shellaced. 

Wires wet, oily or dirty. 

Clean with gasoline moist¬ 
ened cloth. 

Insulation broken or worn 
from wires, especially at 
corners or under clamps. 

Cover with linen tape or 
rubber and linen. Then 
shellac. Friction tape will 
not work. 

Wiring that may rub on 
metal or rods, or that is 
exposed to oil or water 
should be carried in con¬ 
duit or loom with the ends 
taped and shellaced. 

Wrong connections. 

See wiring diagram. 


OPEN CIRCUITS 

160. Open circuits are located by bridging the 
open point with a test wire to which may or may not 
be attached a lamp, an ammeter or a voltmeter. 

Tests may be made with any of the equipment shown 
in the following table. Refer also to sections 103 to 
105. 













!)0 STARTING AND LIGHTING TROUBLES 

TESTING EQUIPMENT 


EQUIPMENT USED 
FOR TEST LINE 

INDICATION WHEN 
POINT OF TROUBLE 
HAS BEEN REACHED 

INDICATION IF 

POINT OF TROUBLE 

HAS NOT BEEN 

REACHED 


CURRENT WILL 

FLOW. 

NO CURRENT WILL 
FLOW. 

Insulated wire 
bared at each 
end. 

Lamps will light, 
horn sound or 
starter operate. 

Parts in trouble 
will remain in¬ 
operative. 

Lamp bulb (car 
voltage) con¬ 
nected to test 
line. 

Test lamp will 
light. 

Test lamp remains 
out. 

Test lamp from 
shop lighting 
system. 

Test lamp will 
light. 

Test lamp will re¬ 
main out. 

Ammeter attached 
to test line. 

Meter indicates 
flow of current. 

Meter pointer re¬ 
mains at “0.” 

Voltmeter at¬ 
tached to test 
line. 

Meter indicates 
battery voltage. 

Meter pointer re¬ 
mains at “0.” 


Conditions of Test. —All switches for parts affected 
(lamps, horn, starter or accessories) should be turned 
on and allowed to remain so. 

161. Testing" Method. —Connect the test line be¬ 
tween the grounded terminal of the battery and a 
clean spot on the car frame or metal as at X in Figure 
27. Normal current flow indicates a poor grounded 
connection from the battery to the frame. 

Next, attach one end of the test line to the un¬ 
grounded terminal of the battery and with the free 
end proceed as follows: 

By following the wiring diagram, touch the test 









WIRING TROUBLES 


91 



Figure 27.—Testing Complete Equipment With Tester in 

Parallel. 



































92 STARTING AND LIGHTING TROUBLES 

line end to each connection in the wiring from the 
battery to the part affected. 

Start at the point A, nearest the battery, and work 
toward the part of the equipment that is affected, 
such as to B, C and D. Then pass to its ground con- 
nection E or back to the battery. 

Touch the test line to the grounded side of the 
battery once in a while to make sure that the line 
and the bulb or meter are operating properly. 

When some one connection is made there will be 
an indication of normal current flow. The trouble 
is between the point then being touched with the test 
line and the last point touched, either in the wiring, 
the connections or the parts of the equipment. 


162. CAUSES AND REMEDIES FOR OPEN CIRCUIT v 


CAUSE 

REMEDY 

Wires completely broken. 

Make soldered joint. Cover 
with rubber and tape, then 
shellac. 

Wires broken inside insula¬ 
tion or under armor cov¬ 
ering. 

Remove insulation or cover, 
make soldered joint, tape 
and shellac. 

Terminals disconnected, 
dirty or loose. 

Clean wire end and binding 
post. Tighten nut or screw 
and fasten with washer or 
lock nut. 

Poorly made joints. 

Make soldered joint. Cover 
with rubber and tape, 
then shellac. 

Wrong connections. 

Follow wiring diagram. 















WIRING TROUBLES 


93 


HIGH RESISTANCE - 

163. Points of high resistance are located by 
bridging them with a test wire to which may or may 
not be attached a lamp, an ammeter or a voltmeter. 
The work is done in the same way as in locating 
open circuits. Refer also to sections 106 to 110. 

Tests may be made with any of the equipment 
listed for locating open circuits. The test bulb from 
the shop lighting system is the least desirable method 
as the voltage is too high to satisfactorily indicate 
an increase of resistance that would seriously affect 
the comparatively low pressure of the battery and 
dynamo. 

The proper connections are shown in Figure 27. 

Conditions of test and testing method are the some 
as for locating open circuits. 


164. CAUSES AND REMEDIES 


CAUSE 

REMEDY 

Terminals loose or dirty. 

Clean wire end and binding 
post. Tighten nut or 
screw and fasten with 
washer or lock nut. 

Poorly made joints. 

Make soldered joints. Cover 
with rubber and tape, then 
shellac. 

Wire of too small gage size 
or of too great length. 

For their length in feet, the 
wires should be of the 
gage sizes given in the 
Tables II and III, or even 
larger. Otherwise their 
length should be reduced 
or a heavier gage substi¬ 
tuted. 

Wrong connections. 

Follow wiring diagram. 














CHAPTER V 


LIGHTING SYSTEM TROUBLES 

200. Troubles in this part of the equipment may 
occur in the lamp cases, the reflectors, the bulbs, the 
bulb sockets or the lamp connectors. 

Electrical faults include those which may cause an 
open circuit, a high resistance, a short circuit, a 
ground or else an overload not due to shorts or 
grounds, but to misuse. 

Mechanical troubles include those due to focusing, to 
the condition of the reflector and to the mounting of 
the lamps on their supports. 

Should tests of the wiring and equipment indicate 
the presence of electrical trouble the following list of 
causes (205) may be referred to and the needed 
remedies applied according to the instructions. The 
mechanical troubles (201) are indicated by failure to 
secure satisfactory light on the road with all elec¬ 
trical conditions correct. 

201. Mechanical Trouble. 

Bulbs out of focus. 

Lamps tilted wrong. 

Reflector tarnished. 

202. Bulbs Out of Focus. —Lamp focusing should 
preferably be done after dark and on the road, or else 
in a place where the light may be thrown straight 


04 





LIGHTING SYSTEM TROUBLES 


. 95 










<X5 STARTING AND LIGHTING TROUBLES 

ahead on a wall about fifty feet from the car. The 
car itself should be level. Conditions are shown In 
Figure 28. 

The bulb should be moved backward or forward 
until the reflected light makes the smallest possible 
beam without circles or dark spots. Good illumina¬ 
tion will be obtained if the light forms a bright circle 
about a foot and one-half in diameter on a wall fifty 
feet from the car. In order to secure a diffused light 
near the car, the bulbs may be thrown slightly out of 
focus. 

203. Lamps Tilted Wrong.—If one lamp seems 
to give better light than the other, or if neither seems 
to light the road properly with the bulbs burning 
brightly, it is quite probable that the cases are 
wrongly tilted on their supports. 

One lamp should be tested at a time by covering 
the other one or by separating its connector. The case 
should be set so that the brightest part of the beam 
of light strikes the road 200 or 300 feet ahead of the 
car and in line with the wheel track for that side of 
the car while the car points straight ahead. 

The highest point of the beam of light should strike 
a wall 60 to 75 feet ahead of the car at a point not 
over 42 inches above the ground with the car fully 
loaded. 

204. Reflector Tarnished.—If the reflectors are 
dirty or tarnished the dust should first be removed by 
blowing or with a stream of water at low pressure. 
If water is used, the surface should be allowed to drv 
by the air alone, not wiped out. 

The mirror may be cleaned with alcohol applied 
with a clean, soft chamois skin held so that there are 



LIGHTING SYSTEM TROUBLES 


97 


no wrinkles. The pressure should be very light and 
the strokes either rotary around the bulb as shown 
in Figure 29 or from back to front. 

The reflector may be polished by moistening a 
chamois skin with alcohol, applying a small quantity 
of jeweler’s rouge and wiping in the same way as for 



Figure 29.—Method of Cleaning Lamp Reflectors. 


cleaning. After the coating has been removed, the 
polishing is completed with more rouge placed on a 
dry chamois skin. 

LAMP CASES AND REFLECTORS 

206. Lamps Loose on Bracket.—In one wire or 
ground return systems the fastening of the lamp case 
to its support is generally depended upon to obtain 
a ground connection as at A in Figure 30. Should 
the bolts, nuts or set screws become loose this connec¬ 
tion becomes poor and the lights become dim, go out 
or flicker. The contact surfaces should be free from 
paint, rust and dirt and should be firmly held to¬ 
gether. 






3 $ 


STARTING AND LIGHTING TROUBLES 


ELECTRICAL TROUBLE 


FAULT 


CLASS OF TROUBLE CAUSED 


Lamp case loose on support.. 
Reflector loose in case. 

Wires loose in lamp case.... 
Bulb old, burned out, poor 


base type wrong. 

candlepower too high... 
candlepower too low.... 

voltage too high. 

voltage too low. 

Socket or connector trouble. 

Lamps lighted with car 

standing. 

Too many lamps used at cn:' 
time . 

Too many accessories. 

Accessories connected wrong. 


Open 

Circuit 

High 

Resistance 

Short 

Circuit 

Ground 

Overload 

See Section 
Number 

* 

* 




206 

* 

* 




207 

* 

* 

* 

* 


208 

* 

* 



* 

209 


* 




210 

❖ 


* 

* 


211 





❖ 

212 


* 




212 


* 




213 

* 




* 

213 

* 


* 

* 

214 

,215 





* 

216 





* 

216 





* 

216 



* 

* 


216 

l Case.— 

In many 

cases 

the 


bulb socket is in metallic contact with the reflector 


and the reflector is depended on to make contact with 
the lamp case in providing a ground connection. 
Should the screws or fastenings holding the reflector 
in place become loose, or should the contact surfaces 
be dirty or rusted, a poor joint is made. The joint is 
shown at B in Figure 30. 

208. Loose Wires in Lamps.—The final connection 











LIGHTING SYSTEM TROUBLES 


90 


to the bulb socket is made through wires inside the 
lamp case and between the outside connector and the 
socket. These wires may become loose while focusing 
the lamp or under other conditions and may then cause 


Figure 30.—Troubles in the Lamp Case and Mounting. 

an open circuit, a short circuit or a ground. It is 
generally necessary to remove the reflector to reach 
the connections, as would be the case at G in Figure 30. 



LAMP BULBS 

209. Bulbs Old, Burned Out or of Poor Quality.— 

The normal life of a bulb is from 100 to 300 hours of 



i 









100 


STARTING AND LIGHTING TROUBLES 


burning. A bulb older than this will probably give 
a poor light even with everything else in good order. 
If the glass shows a dark or mirrorlike deposit, the 
bulb should be replaced with a new one. 

Bulbs having broken filaments may be located by 
looking through them toward the light or by holding 
their contacts on the battery terminals or on lines 
known to be alive. 

Bulbs having carbon filaments, and cheap bulbs in 



Figuie 31.—Typical Socket Construction. 


general, will give a poor light while using a great deal 
of current. The carbon filament bulb gives a light 
with a distinctly yellowish hue when compared with 
those having tungsten filaments. 

210. Bulbs Not Making Contact.—The small 
springs in the bulb socket may be jammed or broken 
so that good contact is not secured; or, in some cases, 
the bulb base may not be long enough to reach the 
plungers in the socket. In such a case, the addition 
of a drop of solder to the contact will remedy the 
difficulty. Socket construction is shown in Figure 31. 

211. Wrong Base Type. —Some lamps may use 


V 

> 


<•> . 































































































LIGHTING SYSTEM TROUBLES 


101 


single contact bulbs while others use those of the 
double contact variety, even on the same car. Should 
a bulb of one type be inserted in a socket of the other 
type no light will be secured and a short circuit may 
result. 

212. Bulbs of Wrong Candlepower. —Bulbs of 

candlepower lower than intended for the lamp will 
not give sufficient light, while bulbs of too high 
candlepower will impose such an added load on the 
system that the battery may gradually loose its 
charge. The proper candlepowers for the various 
bulbs are given below. 


CANDLEPOWER OP LAMP BULBS 


LAMP IN WHICH 

CANDLE- 

USED 

POWER 

Head lamp bright 

15-18 

Dimmers or side 

2-4 

lamps 

Spot lamp 

18-21 

Dash or cowl lamps 

2 

Tail or license lamp 

2 

Body lamps 

- 2-4 


213. Bulbs of Wrong Voltage. —The voltage of 

the bulbs used on a car may be learned by an examina¬ 
tion of the battery, counting the number of cells. . The 
system is of a voltage equal to twice the number of 
battery cells except in the case of some of the older 
two voltage systems in which the lamp voltage may be 
that of the battery, half that amount, or one-fourth 
the battery voltage. 

Lamps wired in series with each other, such as cowl 
and tail lamps on some cars, take half the total volt- 


102 


STARTING AND LIGHTING TROUBi. 


age for each bulb; that is, a six-volt battery would use 
3i/ 2 -volt bulbs for each of the two lamps in series. 

Ford head lamps operating from the magneto use 
0-volt bulbs. 

Bulbs of too low voltage will burn out almost im¬ 
mediately upon being lighted, and until they do burn 
out will give an exceedingly brilliant light. 

Bulbs of a voltage higher than correct will not light 
at all or else will burn but dimly. 

The life of a lamp bulb will be increased by using 
one of slightly higher voltage than normal. The light 
secured will not be so satisfactory and the economy 
is doubtful. 



Figure 32.— Socket and Connector Construction. 


BULB SOCKET AND CONNECTOR 

214. Short Circuited or Grounded.— The con¬ 
nector on the lamp case and the socket carrying the 
bulb are similar in construction and are subject to 













































































































LIGHTING SYSTEM TROUBLES 


103 


the same troubles. Dirt or moisture inside the socket, 
broken insulation or loose strands on the attached 
wires or improper contact with metal of the case may 
cause short circuits or grounds. The remedies are 
apparent when the trouble is found. Several types of 
sockets and connectors are shown in Figure 32. 

215. Open Circuits.—An open circuit in the con¬ 
nector or in the socket may be caused by loose, broken 
or sticking springs or plungers. The socket may be 
loose on its fastenings or the attached wires may be 
broken or loose!. Some types of connectors, especially 
those used for tail or dash lamps, may be turned in 
either of two ways, one direction causing the lamp to 
light, while the opposite way of turning acts as a 
switch and puts the lamp out. It is possible, although 
unlikely, that the socket or connector is of the single 
or double contact type while it should be of the 
opposite kind. 

USE OF LAMPS 

216. Allowing the car to stand with the head 
lamps or spot lamp turned on wastes current and will 
eventually cause trouble. 

If a car is to stand for a long time with the lights 
on, the side or dim lamp next to the curb should be 
turned off by its connector, leaving only one white 
light forward in addition to the tail lamp. This com¬ 
plies with the law for a standing car in most localities. 

It is not necessary to burn both bright and dim 
head lamps, or head lamps and side lamps, at the 
same time while driving. It is also easier to see the 
road and better driving can be done without any 
lamps lighted on the cowl board or in the body at any 
point. 


lot STARTING AND LIGHTING TROUBLES 




Figure 33.—Types of Combination Switches. 































































































LIGHTING SYSTEM TROUBLES 


103 


Substituting bulbs of excessive candlepower for 
those regularly furnished will discharge the battery, 
if the battery is charged and the lamps and reflectors 
are in good condition, the usual size bulbs will give 
ample light. 

The use of nitrogen bulbs of the lowest candlepower 
that gives the required light will economize current, 
this type being most efficient. 


LIGHTING SWITCH, FUSES AND CIRCUIT BREAKERS 

220. Lighting or Combination Switch. —Troubles 
occurring at the terminal connections of the lighting 
switch have been treated under the head of “Wiring 
Troubles” and are not considered here. Having 
located the trouble in the switch, its nature and cause 
must be found by examination. Several types of 
switches are shown in Figure 33. 


221. SHORT CIRCUITS 

CAUSE 

Switch housing wet or oily 
inside or out. 

Internal shorts caused by 
bent blades, loose parts 
or grounded wires. 

Wrong connections at ter¬ 
minals. 

222. OPEN CIRCUITS 

CAUSE 

Contacts dirty, bent, loose 
or burned. 

Rotary switch turned back¬ 
ward. 

Wrong connections. 


OR GROUNDS IN SWITCH 
REMEDY 

Clean with gasoline moistened 
brush or cloth. 

Open switch, tighten and in¬ 
sulate parts. 

See wiring diagram or follow 
wires. 

OR PIIGH RESISTANCE 
REMEDY 

Clean with fine emery cloth 
^and tighten. 

Disassemble and replace 
parts. 

See wiring diagram or follow 
lines. 


106 


STARTING AND LIGHTING TROUBLES 


LIGHTING FUSES 

230. Fuse Burned Out. —This condition indicates 
the presence of a short circuit or ground which should 
be located and remedied before the fuse is replaced. 

The fuse itself may be tested with either form of 
test lamp, with an ammeter or a voltmeter. Any tester 





Figure 34.—Testing for Blown Fuses. 

should be placed in series with the fuse and attached 
to the battery or other current source, as at A in 
Figure 34. 

The fuse may be tested while still in place with a 
voltmeter by first turning on the switches, then touch¬ 
ing the voltmeter leads to the ends of the fuse as at 
































LIGHTING SYSTEM TROUBLES 107 

B, Figure 34. A high voltage reading indicates a 
blown fuse (104). 

In testing for a short circuit or ground which has 
caused a fuse to blow, the test lamp, ammeter or 
voltmeter may be inserted between the fuse clips as 
at C in Figure 34 in place of at battery, inasmuch 
as only the line reading away from the blown fuse 
need be examined. As long as the lamp remains 
lighted or as long as the meter shows a current flow, 
the trouble remains. When the fault is removed, 
the lamp will go out or the meter will show no flow 
of current (119-120). 

Lighting system fuses should be of the following 
capacities: 

Head lamp line. 

Side or dim lamps only 
Tail and dash lamps... 

All lamps. 

Horn . 

Under no conditions should the fuse be replaced 
with one of larger capacity than normal or with a 
piece of wire as such practices will eventually lead 
to more serious trouble. 

231. Fuse Making Poor Contact. —The clips may 
be sprung or loose, in which case the fuse should be 
removed, the clips bent together, and the fuse re¬ 
placed. 

A small piece of dirt between the fuse and clips 
may prevent good contact. Turn the fuse around in 
the clips to dislodge any such particles. 

If the ends of the fuse or the clips are found very 
dirty or corroded, they should be cleaned with fine 
emery cloth. 


.15 ampere 
5-8 ampere 
. 5 ampere 
.20 ampere 
.15 ampere 







108 


STARTING AND LIGHTING TROUBLES 


CIRCUIT BREAKERS 

240. Two types of these instruments are in use; 
one in which the breaker remains open when once 
acted upon by an excessive flow of current, and the 
other in which the breaker opens and closes rapidly 
as long as the excess flow continues. A Delco circuit 
breaker is shown in Figure 35. 


Contact Points 

\ 



Coil 

_ j ^ a. ^ j > - 


Armature 


Figure 35.—Delco Circuit Breaker. 

While it is possible for the parts to become short 
circuited or burned out, it is highly improbable, as 
the instrument has very little work to do and is gen¬ 
erally built in a very rugged way. 

In case the tests have shown a point of open circuit 
or high resistance at the circuit breaker, it should be 
examined for dirty contacts which may be cleaned 
with emery cloth, and for loose connections. 

Should a circuit breaker indicate a short or ground 
in the svstem, it should not be closed or forced to stav 
closed until the original trouble is located and re¬ 
moved. 

The spring tension should never be increased to 
overcome opening of the breaker, as it is a safety device 
and such changes would allow damaging currents to 
flow without any protection to other parts of the 


svstem. 









































CHAPTER VI. 


DYNAMO TROUBLES 


300. The troubles considered in this chapter 
affect the brushes, commutator, armature, fields and 
housing of the dynamo; but do not include those 
having to do with the cut-out or output regulation. 


Brushes 


Commutator 


Armature 


Fields 


Making poor contact (321). 

Binding or loose holders (322). 
Wrong tension or pressure (323). 
Circuit open (324). 

Worn out, too short (325). 

Position wrong (326). 

Wrong size or material (327). 

Dirty (341). 

Rough, grooved or pitted (342). 
High mica (343, 344). 

Loose, high or low segment (345). 

Grounded (361). 

Open circuited (362). 

Short circuited or double ground 
(362-364). 

Loose bearings or end play (365). 

Open circuited (383, 384). 

High resistance (385). 

Grounded (386). 

Shorted (387). 

Reversed or dead (388, 389). 

Pole piece or machine defects (390). 


100 


110 


STARTING AND LIGHTING TROUBLES 


Housing Dirty (307). 

Wet (307). 

Drive broken or loose. 

Some of these troubles may be located by examina¬ 
tion, others by the action of the dynamo while gen¬ 
erating or running and still others by special tests 
which will be explained. Any or all of them will 
cause the dynamo output in amperes and its voltage 
to be lower than normal, or may cause a total failure 
to generate. 

DYNAMO OUTPUT TESTS 

301. With the engine idle, disconnect one of the 
leads from the battery. Turn on all lighting switches, 
touch the disconnected lead to the battery long enough 
to start the engine with the crank, then remove it 
again. If, as the engine is gradually speeded up to a 
point corresponding to 15 or 20 miles an hour of the 
car, the lamps light and burn normally, it indicates 
that the dynamo is in good order. If the lamps remain 
out or light dimly, the dynamo, cut-out or regulating 
system is out of order. 

Replace the cable on the battery and test the dynamo 
as in 302 or 303. 

302. Low Voltage Lamp Test. —Open the dynamo 
housing and connect a test lamp (20-25) of the voltage 
used on the car between the two main brushes or 
between the positive and negative brush holders if 
more than two brushes are used (do not consider the 
regulating or third brush). If one brush or one brush 
holder is grounded, the test lamp may be connected 
between the ungrounded brush and the metal of the 
dynamo. See Figure 36. 


DYNAMO TROUBLES 111 

AVith the dynamo running, the test lamp should 
light and burn brightly. If the lamps on the car 
failed to light or burned dimly in the preceding test, 





Figure 36.—Dynamo Voltage Test. 













112 STARTING AND LIGHTING TROUBLES 

while the test lamp on the brushes now burns 
brightly, it indicates that the trouble is in the cut-out 
or regulating devices or else in the charging system 
between the dynamo and the lighting switch, but not 
in the dynamo proper as considered in this chapter. 



Figure 37.—Testing Voltage at Dynamo Brushes. 


If the test lamp fails to light or burns dimly it in¬ 
dicates trouble in the dynamo itself and tests start¬ 
ing at 304 should be made. 

303. Voltmeter Test. —A voltmeter may be con¬ 
nected to the brushes as shown in principle by Figure 
37. A voltage reading above that of the battery 









DYNAMO TROUBLES U3 

(according to the number of cells multiplied by two) 
indicates that the dynamo itself is operating properly 
and if the car lamps failed to light briefly in the first 
test (301), it shows that the trouble is between the 
dynamo and lighting switch, in the cut-out or regu¬ 
lating system. If the voltage shown is lower than that 
of the battery, it indicates dynamo trouble and the 
following tests should be made. 

PRELIMINARY EXAMINATION OP DYNAMO 

With the brush and commutator covers removed 
from the dynamo the following examination should 
be made: 

304. Brush Test.—With the dynamo running and 
the test lamp or voltmeter across the brushes, or with 
an ammeter in series between the dynamo and bat¬ 
tery, press lightly on each of the brushes and try 
moving them around so that a different bearing is 
secured on the commutator. Should this cause the 
test lamp to light, the voltmeter to show normal volt¬ 
age or the ammeter to show a normal charge, it 
indicates brush trouble as follows: 

Making poor contact (321). 

Spring pressure too light (323). 

Binding or loose holders (322). 

Brushes worn out, too short (325). 

These faults, together with their remedies, are 
treated in this chapter under the sections given by 
the above numbers. 

305. Commutator. — The commutator surface 
should be examined for the following: 

Dirty or blackened (341). 

Mica flush with copper bars (343). 



114 STARTING AND LIGHTING TROUBLES 

Rough, grooved or pitted (342). 

Loose, high or low segments (345). 

If any of these conditions are found, the remedy 
explained under the given section numbers should be 
applied. 

If only one point on the commutator is burned or 
blackened it probably indicates that one or more arma¬ 
ture coils attached to the commutator near this point 
are burned out or otherwise open circuited (362). 

306. Armature.—The armature should be grasped 
and moved up and down as well as endwise to locate 
loose bearings on the armature shaft or excessive end 
play. These troubles and their remedies are treated 
under section 365. 

307. Housing.—The interior of the dynamo case 
must be kept free from excessive collections of car¬ 
bon and copper dust and of oil or grease. These dust 
collections may be blown out with compressed air or 
they may be wiped away with a cloth moistened with 
kerosene. Gasoline should not be used for cleaning 
the interior of the dynamo as it would partially dis¬ 
solve the shellac and varnish which is depended upon 
for insulation. Accumulations of dirt should be re¬ 
moved when overhauling, and this should be done 
once a year at least. 

If the interior of the dynamo has become thoroughly 
wet, so that it will not readily dry out by simply leav¬ 
ing the covers off, the machine should be removed 
from the car, all covers taken off, and the dynamo 
baked for about 24 hours in a heat between 200° and 
230° Fahrenheit. 

308. Sparking at Brushes. —The dynamo should 
be run with the brush and commutator covers re- 


DYNAMO TROUBLES 115 

moved and the point of contact between brushes and 
commutator watched, preferably in a darkened place. 
Excessive sparking may indicate any of the following: 

Brushes making poor contact (321). 

Brush holders binding or loose (322). 

Brush spring tension too light or too heavy (323). 

Brushes worn too short (325). 

Brush position wrong (after repairs have been 
made) (326). 

Brushes of wrong size or of wrong material (327). 

Commutator blackened or dirty (341). 

Commutator rough, grooved or pitted (342). 

Commutator mica flush with, or above, copper seg¬ 
ments (343). 

Armature open circuited (362). 

Armature short circuited (364). 

309. Heating of Dynamo. —Should the dynamo 
become too hot for the bare hand after running for 
some time, it may indicate any of the following: 

Armature grounded (361), short circuited (362, 
364), or loose in bearings (365). 

Fields grounded (386) or short circuited (387). 

MOTORING TEST OF DYNAMO 

310. With the battery charged and properly con¬ 
nected and with the cut-out closed, the dynamo will 
run as a motor provided the drive connection is tem¬ 
porarily removed. In some types of equipment the 
dynamo drive shaft includes an overrunning clutch 
which allows the machine to run freely as a motor 
without opening the drive connection. 

If the cut-out is of the electromagnetic type the con¬ 
tacts may be pressed together by hand, while if it is 



116 STARTING AND LIGHTING TROUBLES 

of the manual type the switch may simply be closed 
as for running. 

In order to make this test of the most value, an 
ammeter should be in circuit between the battery and 
dynamo so that the current may be known and its 
action watched. See Figure 48 and section 382. 

If the dynamo operates as a motor and at a fair 
speed, without excessive consumption of current and 
without any great fluctuation in the current flowing, 
it indicates that the brushes, commutator, armature 
and fields are in good order and no trouble should be 
found in causing the machine to generate when driven 
by the engine. 

311. No Motoring.—Should the dynamo fail to 
run when the cut-out is closed and with the drive free, 
it indicates any of the following troubles, all of which 
are treated in detail under their proper section head¬ 
ings. 

Brushes binding or loose in the holders (322). 

Brushes circuit open, pig tails off (324). 

Brushes worn out, too short (325). 

Commutator dirty or blackened (341). 

Armature short circuited (362-364). 

Armature open circuited at two points on opposite 
sides (363). 

Fields open circuited (383, 384). 

Fields short circuited or grounded (386, 387). 

Fields reversed or dead (388, 389). 

312. Slow Motoring*. —Should the dynamo run 
very slowly as a motor, or should the current con¬ 
sumption be excessive, it may indicate the following 
troubles: 

Brushes making poor contact on commutator (321). 

Brushes worn short (325). 


DYNAMO TROUBLES 


117 


Commutator dirty, rough or grooved (341, 342). 
Armature short circuited or grounded (361-364). 
Fields short circuited or grounded (386, 387). 
Field circuit contains high resistance (385). 

Field connections reversed or wrongly made (389). 
313. Fluctuating Current While Motoring. — 
Should the ammeter show great changes of current 
flow or should the speed of the dynamo be irregular 
while motoring, it may indicate any of the following 
troubles: 

Brushes making poor contact with commutator 
(321). 

Brushes binding or loose (322). 

Commutator dirty, rough, pitted or grooved (341, 
342). 

Mica above copper on commutator surface (343). 
Armature grounded or short circuited (361-364). 
Armature open circuited (363). 

Armature bearings loose or have excessive end play 
(365). 

320. BRUSH TROUBLES 

TROUBLE REMEDY 

Poor contact with commu- Fit with sandpaper, 
tator. 


Binding or loose in holder 
or holder binding. 

Spring tension too light. 
Spring tension too great. 
Spring broken or loose. 

Circuit open. Pig tail brok¬ 
en or disconnected. 


Fit brush with fine file. Clean 
and set holder. 

Test tension with scale and 
adjust spring. 

Clean and tighten fastenings 
or solder the connection. 


Worn out. Too short. Holder 
touching commutator. 


Replace with new brushes 
and fit them with sand¬ 
paper. 



118 


STARTING AND LIGHTING TROUBLES 


Position wrong. May occur 
after repairs have been 
made. 

Wrong size or kind. Too 
wide. Copper or copper 
gauze in place of carbon 
or graphite. 


Set brushes at point on com¬ 
mutator that shows least 
tendency to spark. 

Obtain correct brushes from 
maker of machine or from 
reliable supply house. 


321. Poor Brush Contact. —If pressing on the 
brushes or rocking them in their holders while the 



Figure 38.—Sanding the Brushes. 


dynamo is running causes a decided rise in the dy¬ 
namo output or an increase in the brilliancy of the 
lamps, it indicates poor contact of the brushes with 
the commutator. 

It should be noted that a dirty or roughened com¬ 
mutator will prevent good contact regardless of the 
fitting of the brushes, and in such a case sections 341 
and 342 should be referred to. 
























DYNAMO TROUBLES 


119 


The brashes are fitted to the curve of the commu¬ 
tator by drawing a strip of fine sandpaper between 
the brush and commutator with the sand side toward 
the end of the brush as shown in Figure 38. 

Sandpaper of the grade known as “00” should be 
used and if it has been previously used or is old, so 
much the better. A strip should be cut which is 
slightly wider than the end of the brush, the brush 
should be lifted and the paper inserted with the 
smooth side next the commutator. The brush should 
then be released, but no additional pressure applied, 
as the brush spring provides ample tension for the 
work. 

The sandpaper should be wrapped around the com¬ 
mutator for as great a distance as possible and drawn 
so that it follows the curve. If drawn out flat the 
brush sides will not be properly fitted and sparking 
will result. 

By drawing the sandpaper back and forth a num¬ 
ber of times the brush end will be properly fitted over 
its entire concave surface and its full current carry¬ 
ing capacity will be made available. 

322. Brushes Binding or Loose.— If the brushes 
slide in stationary holders they must make an easy fit, 
yet must not be so loose that there is danger of wedg¬ 
ing or binding. Should it be found that the brush 
fits too snugly at some point it may be carefully 
dressed with a fine file. Opposite sides should be kept 
parallel with each other. A stationary holder is 
shown at the left in Figure 39. 

If the brushes are fastened to a pivoted holder the 
fastening should be secure and the pivot joint of the 
holder should work freely without oil, but without 
being loose enough to allow poor brush contact under 


120 STARTING AND RIGHTING TROUBLES 

some conditions. The joint should be free from dirt, 
oil or rust, especially in cases where it is depended 
upon to carry current to or from the brush. A 
pivoted holder is shown at the right in Figure 39. 

323. Spring Tension Wrong. —The tension on the 
brush springs may be measured by the use of a small 
spring balance attached to the spring at the brush end 
or to the holder (if of the pivoted type), also at the 
brush end. This is shown in Figure 40. 



Figure 39.—Brush Mountings. 


For brushes of the usual size the tension for those 
in the dynamo should be between 1/2 and 1 pound, for 
those in the motor between 1 and 2 pounds. Very 
small brushes should have proportionately less ten¬ 
sion, while if they are very large, the tension should 
be greater than that mentioned. As a general rule 
the pressure should amount to about 1y 2 pounds for 
each square inch of brush surface bearing on the com¬ 
mutator. 

The brush tension should be great enough to cause 





































DYNAMO TROUBLES 


121 


good contact at all speeds without sparking, yet it 
should be as light as will meet these conditions because 
excessive pressure on the brushes causes rapid wear 
of both brush and copper in the commutator. 

324. Brush Circuit Open. —By consulting the 
wiring diagram, the current path to the brushes may 
be followed. A short length of flexible cable, called 
the brush pig tail, is usually attached directly to the 
brush or to the holder; if the brush is fastened to that 





part. Both ends of this connection should be securely 
fastened and, of course, it should be unbroken as well 
as free from short circuits. 

By separating the brush from the commutator with 
a piece of paper, the circuit from the brush to any 
point may be tested with any form of circuit tester 
having one end attached to the brush which is then 
insulated from the commutator. 

325. Brush Worn Out.—Brushes should be in- 

. V 

spected for length about once in 2000 miles driving. 














122 


STARTING AND LIGHTING TROUBLES 


If it is found that they can wear only about inch 
before failing to make contact or before parts of the 
brush holder will touch the commutator, the brushes 
should be replaced with new ones. After the new 
brushes are attached, they should be fitted with sand¬ 
paper as already described (321). 

In case of doubt as to the brush length being suffi¬ 
cient, they should be replaced, because they may not 
lie short enough to fail completely, yet too short to 
make good contact, with consequent damage to the 
commutator surface. 

326. Brush Position Wrong. —In case the dynamo 

lias been taken apart and re-assembled, there is a pos¬ 
sibility that the brushes have been replaced so that 
they do not bear on the commutator in the correct 
position relative to the pole pieces. 

The brushes are placed so that they short circuit 
adjacent commutator segments between which there 
is the smallest difference of voltage as they pass under 
the brush. If the brushes are in any other position 
around the commutator it will result in a lower out¬ 
put and excessive sparking. The best position can 
be found by trial for the least sparking with the dy¬ 
namo running. 

When a dynamo is to be taken apart and when the 
brush riggings are to be removed, their position should 
be carefully marked on the parts to which they attach 
so that correct replacement may be made. 

327. Brushes of Wrong Size or Kind. —The length 

(measured in line with the armature shaft) should be 
a little less than the length of the commutator seg¬ 
ments. , 

Brushes should always be obtained from the maker 
of the dvnamo or from some house that makes a spe^ 


DYNAMO TROUBLES 


123 


cialty of supplying brushes for replacement. 

Dynamo brushes are generally made from carbon 
or graphite and they may be of special compositions 
containing some form of graphite lubricant. Copper 
or copper gauze brushes should never be used in a 
dynamo unless it is known that the machine was de¬ 
signed for them, this rarely being the case. 

328. Brushes Squeak. —This may be caused by 
poorly seated brushes, wrong tension on brush spring 
or by a hard spot in the brush. 


I 

340. COMMUTATOR TROUBLE 


TROUBLE 

Dirty or blackened. 
Rough, pitted or grooved. 

High mica. 

Loose, high or low bar. 


REMEDY 

Clean with cloth or sand¬ 
paper. 

Remove and take off small cut 
in lathe, then undercut and 
dress surface. 

Undercut according to in¬ 
structions. 

Remove armature and inspect 
fastenings. 


The troubles considered here as those of the com¬ 
mutator are of a mechanical nature only. Electrical 
troubles are treated under the head of “Armature 
Trouble” (360-365), as under such conditions the 
commutator is considered to be a part of the armature. 

341. Commutator Dirty. —Should an inspection 
show that the commutator surface is blackened or 
dirty, it may be cleaned by holding a clean cloth 
slightly moistened with light oil or vaseline against 
the copper surface while the dynamo is running. Do 
not use w;i f a for cleaning. 

If this method does not remove the discoloration the 


124 


STARTING AND LIGHTING TROUBLES 


work may be done with “00” sandpaper. The paper 
should be cut wider than the brush, the brush lifted 
and the paper placed between the brush and commu¬ 
tator with the sand side toward the commutator. The 
brush should then be released, its spring providing 
sufficient pressure for the work. Do not use emery 
cloth as emery will short circuit the commutator bars. 
The method is shown in Figure 41. 



Now run the dynamo until the commutator takes a 
clean, bright appearance, after which remove the sand¬ 
paper and wipe with a clean cloth. After dressing 
with sandpaper, the commutator should be carefully 
examined for particles of copper bridging between 
adjacent copper segments. If any such are found, 
they should be carefully removed with the tip of a 
knife blade. 

342. Commutator Rough. —If the commutator sur¬ 
face is grooved, pitted or very rough, the armature 
should be removed and placed in a lathe where a very 





DYNAMO TROUBLES 


125 


fine cut may be taken from the surface of the com¬ 
mutator so that it is true and smooth. It may be 
necessary to fit new brushes (321) in case the old ones 
were nearly worn out. 

After dressing the commutator in a lathe, it is 
necessa^ to undercut the mica insulation according to 
the method next described. 

343. Undercutting Mica. —After a dynamo has 
run for some length of time the copper surface of the 




Figure 42.—Undercutting Commutator Mica. 


commutator segments will wear down until finally 
the mica insulation between the bars is flush with their 
surface. The mica is harder than the copper and does 
not wear away so fast, the result being excessive 
sparking and burning at the brushes due to the poor 
contact. 

If it is found that the mica is flush with the copper 
or slightly above it, the armature should be removed 





126 


STARTING AND LIGHTING TROUBLES 


and preferably placed in a lathe to be trued up with 
a very light cut over its surface. It is then ready for 
undercutting as shown in Figure 42. 

With the armature held in a vise the mica between 
the commutator segments is cut out to a depth of 
1/64 to 1/32 inch by using a piece of hack saw blade 
or a small knife hie. In either case the cut should be 
wide enough to pass a very little distance into the cop¬ 
per at each side of the mica so that there is no possi¬ 
bility of mica being left against copper bars in the 
cut portion. The blade should be ground off to the 
correct width. 

The slots between the bars should be perfectly 
square, not grooved or rounded and, as stated, should 
be a little wider than the thickness of the mica. 

344. After the undercutting is completed a care¬ 
ful examination should be made to see that there are 
no copper pieces bridging between the commutator 
segments. A small three-cornered file may be used to 
slightly bevel the edges of the slots to insure freedom 
from such short circuits. 

345. Loose, High or Low Bars. —The commutator 
segments are often mounted as shown in Figure 43. 
The armature shaft is covered with an insulating ring, 
the segments are assembled on top of the ring with 
mica insulation between each segment, an insulating 
washer is placed at the end away from the armature 
and the whole is held together by a nut or by screws. 

The inner side of the segments is dovetailed and 
undercut so that the fastenings fit into the grooves 
and hold the segments securely with the nut tightened. 
In some cases, the segments are simply set into an 
insulating compound which is moulded in place while 
heated. 


DYNAMO TROUBLES 


127 


Looseness of the bars calls for removal of the arma¬ 
ture and an inspection of the mechanical methods of 
fastening. 






























































































128 


STARTING AND LIGHTING TROUBLES 


360. ARMATURE TROUBLES 


TROUBLE 

SYMPTOMS 

REMEDY 

Grounded arma¬ 
ture or commu¬ 
tator. 

Low charge rate, 
heating or 
sparking. 

If the trouble, when lo¬ 
cated as to its kind 
cannot be found by 
inspection, the arma¬ 
ture should be re¬ 
placed or returned to 
its makers unless the 
shop has special fa¬ 
cilities for rewinding. 

Examine the exposed 
leads between com¬ 
mutator and arma¬ 
ture coils and the ex¬ 
posed portions of the 
coils. 

Open circuit in 
armature or 
commutator 
leads. 

Usually causes 
sparking and 
burning on the 
commutator 
near the 
break. 

Short circuit in 
armature or 
commutator. 

May cause a 
bright spot on 
the commu¬ 
tator, also ex¬ 
cessive heat¬ 
ing. 

Loose bearings 
or end play in 
armature shaft. 

Low output or 
heating. 

Bearings should be re¬ 
newed or adjusted 
properly. 


/ * . 


It should be borne in mind that the armature and 
the commutator with their connecting leads are con¬ 
sidered as one electrical unit in the following tests. 

361. Armature Grounded. —This test should al¬ 
ways be made before those for locating short circuits 
or open circuits because two grounds might cause and 
act like a short circuit. 

The brushes should be separated from the commu¬ 
tator with strips of paper. Then touch one lead of 
a circuit tester to the commutator surface and the 
other lead to the metal of the dynamo or the armature 
shaft as shown in Figure 44. If the lamp does not 
light or if the meter being used does not indicate a 
flow of current, there are no grounds. If the lamp 


















L> Y NAMO TROUBLES 


120 


lights or the meter shows current flow, a ground exists 
which may be located by examination. 

362. Open or Short Circuit in Armature. —This 
test will tell whether either an open or short circuit 
exists. The following tests (363, 364) will tell which 
of these troubles is present. 

Both the positive and negative brushes should be 
left in contact with the commutator, but all outside 
leads must be disconnected from all but one and pref- 



Figure 44.—Test for Grounded Armature or Commutator. 


erably from all of the brushes. That is, all the 
brushes possible must be insulated from everything 
except the commutator. If one brush is permanently 
grounded, it is, of course, impossible to isolate it, but 
the test can be made anyway. 

Connect one dry cell between the brushes and have 
an ammeter in the circuit and in series with the dry 
cell. This combination will give a flow of about 10 




i:X> STARTING AND LIGHTING TROUBLES 

amperes in most cases. The connections are shown 
in Figure 45. 

Now turn the armature slowly by hand while 
watching the reading of the ammeter. If there is a 
noticeable change in the reading at any point, it in¬ 
dicates either an open circuited or short circuited coil. 
If the reading is steady, no trouble is indicated. 

The brush contact and the commutator surface 
should be in good condition for this test. 



Figure 45.—Test for Open or Short Circuit in Armature. 


363. Open Circuit in Armature. —The brushes 
should be isolated as in the preceding test (362) and 
a dry cell connected directly to the brushes without 
the ammeter in circuit as in Figure 46. 

A voltmeter reading up to about 3 volts should be 
used with leads attached to each of its terminals and 
ending in clean, sharp test points. These voltmeter 
leads should be successively placed on each pair of ad- * 
jacent commutator segments all the way around the 














DYNAMO TROUBLES 


131 


commutator and the voltage reading noted for each 
connection. Do not bridge more than one pair of 
segments each time. 

On one half of the armature, as divided by the two 
brushes, low readings of about the same value will be 
obtained between each pair of adjacent segments. This 
side, therefore, does not contain the open circuit. 

On the opposite side no reading at all will be ob- 



Figure 46.—Test for Open Circuit in Armature. 


tained between the adjacent segments until the pair is 
bridged between which lies the open circuit. At this 
point there will be practically a full voltage reading, 
thus indicating the location of the trouble. 

This test should be made before that for locating 
shorted armature coils (364) because an open circuit 
would probably burn out the voltmeter as used in 
fli<* test for shorted coils. 

364. Short Oircuit in Armature.— This test should 









132 


STARTING AND LIGHTING TROUBLES 


only be made after those for grounds and for open 
circuits (361 to 363) have been completed. 

The brush conditions and the connection of the dry 
cell to the brushes are the same as in the preceding 
test (363) for open circuits. In this case, however, 
use the test leads attached to the 1/10 (0.1) volt scale 
of the voltmeter. Take especial care not to bridge 
more than one mica, that is, do not bridge between 
more than two commutator segments at one time or 
the meter may be burned out. 

The voltage between each pair of adjacent segments 
is measured by touching the test points to the seg¬ 
ments, one pair after another all the way around. 
The reading should be noted in each case and all 
should be about the same. 

If any reading drops almost to zero on F'e volt¬ 
meter, it indicates a short circuit in the armature coil 
between the two segments then being touched with the 
test points. If the reading is practically zero, it indi¬ 
cates that all of the turns of the coil are shorted out, 
while if the reading is only slightly lower than nor¬ 
mal, it indicates that only a small part of the entire 
coil is shorted. The connections are shown in Fig¬ 
ure 46. 

365. Loose Bearings or End Play. —The end play 

of the armature shaft should be adjusted to very close 
limits by the bearings or bearing housings. Some 
type of ball bearing is generally used on the armature 
shaft of dynamos. If these bearings are of the adjust¬ 
able type, the end play is easily removed, while if 
they are of the ordinary annular type, the bearing- 
may generally be shifted endwise in its housing by 
the use of spacers as shown in Figure 47. A slight 
amount of end play should remain in order to allow 


DYNAMO TROUBLES 


for any expansion of the armature shaft due to 
heating. 

If the armature has been removed from the dynamo 
frame, the brushes should be held back while it is 
being replaced, the armature should then be entered 
part way and when the commutator is under the 
brushes, they may be released. The bearings should 
be lightly tapped to take up any end play. 



Figure 47.—Armature Shaft Mounting. 


If, with the bearings removed, the races do not turn 
freely in relation to each other, they should be thor¬ 
oughly washed in gasoline and rapped smartly down 
on their sides to remove any foreign matter. 

If the bearings are so worn as to allow much move¬ 
ment of one race toward and from the other while 
the bearing is laid flat on a surface plate, the entire 
bearing should be replaced with a new one. 







































STARTING AND LIGHTING TROUBLES 


r 


134 


380. FIELD TROUBLES 


TROUBLE 

SYMPTOMS 

REMEDY 

Field fuse trou¬ 
ble, burned 
out, loose, etc. 

No dynamo out¬ 
put. 

Indicates open charging 
circuit. See also 
“Fuse Troubles." 

(230, 231) 

Open circuited 
field. 

No dynamo out¬ 
put. No cur¬ 
rent through 
field. 

If the trouble, when lo¬ 
cated as to kind, can¬ 
not be found by in¬ 
spection, the field coil 
should be returned to 
its makers unless the 
shop has special fa¬ 
cilities for rewinding. 

Examine the exposed 
leads between the 
coils and between the 
coils, brushes and ter¬ 
minals. 

High resistance. 

Low dynamo out¬ 
put. Low field 
current. 

Grounded field 
circuit. 

iiOw output or 
no output. 
Excessive 
field current. 

Short circuit 
within one 
winding or be¬ 
tween wind¬ 
ings. 

Low output or 
no output. Ex¬ 
cessive field 
current. 
Excessive 
beating. 

Fields reversed 
or dead. 

No output. SIoav 
building up of 
voltage. 

Closing cut-out will en¬ 
ergize pole pieces to 
rema^netize. 

Pole pieces loose 
or poorly ma¬ 
chined. 

Low output. 
Heating. 

Pole pieces must fit 
smoothly to frame 
and be tightly in 
place. 


381. Field Tests. —To make any tests of the field 

windings it is necessary to isolate both ends of the 

winding if possible, or one end at least. If neither 

end can he insulated, the outside connections may 

«• 


I 

























DYNAMO TROUBLES 


185 


make most of the held tests useless. The wiring dia¬ 
grams will show the held connections. 

The helds may generally be isolated by disconnect¬ 
ing the battery from the dynamo, by placing paper 
between each brush end and the commutator and by 
removing all wires and attachments from the dynamo 
and brush terminals. 

If the dynamo is of the third brush type, the third 
brush may be lifted and used for testing, as it forms 
one end of the held winding. 

382. Motoring Current. —The condition of the 
helds may often be indicated by the amount of cur¬ 
rent required to run the dynamo as a motor. To 
make such a test, the drive should be disconnected 
unless it includes an overrunning clutch that will 
allow the dynamo to run freely (310-313). 

With an ammeter in the circuit, the cut-out may 
then be closed or the battery may be connected directly 
with the dynamo and the amperage noted. Practically 
all machines cf the .types usually found take a current 
of from 1 to 3 amperes for this operation. The exact 
current draw depends on the make and type, but it 
may safely be assumed to fall between these limits. 
A current below 1 ampere would then be considered a 
low motoring current, while one greater than 3 or 3V2 
amperes would be considered too high. 

A low motoring current may indicate a high resist¬ 
ance (385), wrong connections (389) or poor contacts 
at the field fuse. 

A high motoring current may indicate grounds 
(386), short circuits (387) or wrong connections in 
the fields (389). 

In testing the current drawn while operating the 
dynamo as a motor, the wiring diagram should be con- 


136 STARTING AND LIGHTING TROUBLES 

suited before connecting the ammeter, and care should, 
be exercised to insert the meter in a line that carries 
all the current between battery and dynamo. In the 
case illustrated by Figure 48, the meter might be 
placed in lines A, B or C with correct results; yet, 



Figure 48. —Connections for Typical Generating System. 


if placed in line D, only the field current would be 
measured. From an examination of external wiring it 
is not always possible to determine the right line to 
use, hence the necessity for consulting the internal 
wiring diagrams. 

383. Field Fuse Burned Out. —If it is found by 























DYNAMO TROUBLES 


137 


examination that the field fuse is burned out, it indi¬ 
cates that there is a break or poor connection between 
the dynamo and the battery. This trouble should 
be found by the tests given for “Open Circuits” (103- 



Figure 49.—Test for Open Circuited Field Windings. 


105, 160-162) or “High Resistance” (106-110, 163- 
161) in the Chapter on “Wiring Trouble.” 

If it is impossible for the current generated by the 
dynamo to flow freely to the battery, an excessive 
amperage is forced through the field circuit as the 
only remaining path. This excessive current burns 
out the field fuse, thus protecting the field windings. 

384. Open Circuited Field.— This test may be 
made with either low or high voltage test lamps or 
with a voltmeter. In any case, the test points should 























138 


STARTING AND LIGHTING TROUBLES 


be placed on the two ends of the field winding to be 
tested. Typical connections are shown in Figure 49. 
If the test lamp lights or if the voltmeter shows a 

reading, it indicates that the field winding is not open 
circuited. If the lamp fails to light or if the volt¬ 
meter indicates no voltage, it shows that the field cir¬ 
cuit is open. 



It should, of course, be first ascertained that the 
field fuse is not burned out and that it is making good 
contact in its clips. 

385. High Resistance in Field. —The low voltage 
test lamp may be connected to the two ends of the 
field as for locating open circuits. If the lamp burns 
dimly, it indicates high resistance at some point. 

The voltmeter mav be connected by its leads to the 
two ends of the field while current from a battery is 









DYNAMO TROUBLES 


139 


allowed to flow through the field as shown in Figure 
50. If a very low reading is shown by the voltmeter, 
it indicates that the field does not contain excessively 
high resistance. If the reading on the voltmeter is 
nearly as high as that of the battery being used, it 
indicates a point of high resistance or an open circuit 
in the field lines. 

386. Grounded Fields. —To test for grounds it is 



Figure 51.—Test for Grounded Fields. 


necessary that both ends of the field be isolated, or, 
at least, that no part of the field be connected with 
the metal of the dynamo. In case one end of the field 
winding is permanently grounded (as shown by the 
wiring diagrams) this test cannot be made without 
special information. 

By using either the high or low voltage test lamp, an 
ammeter or a voltmeter as shown in Figure 51, and 
with one test point touching a clean point on the 
metal of the dynamo and the other touching one end 
of the field, grounds will be indicated. 






140 


STARTING AND LIGHTING TROUBLES 


If the lamp lights or if the meter shows a flow of 
current, it indicates a ground. If the lamp remains 
out or if the meter shows no current or voltage, it 
shows that the field is not grounded. 

In case one end of the field is permanently grounded 
it would be necessary to know or to calculate the 
resistance of the field winding when in good condi-* 
tion, or else to have access to a similar winding known 
to be in good order. If there are several field coils, 
each may be tested and the results compared. Any 
great variation for one coil, indicates that it is at 
fault. 

Then, with an accurate ammeter and one dry cell 
connected in series with the field and the ground of 
the dynamo metal frame, as in Figure 52, the amper¬ 
age flowing through the good field can be found. If. 
with the field being tested, the amperage is much 
greater than this flow, it indicates that the field is 
grounded at some point between the permanent 
ground and the point being touched with the test line. 
This greater flow is allowed because of the lower re¬ 
sistance through the accidental ground connection 
and the metal of the frame. 

387. Short Circuited Fields. —Short circuits in 
the field circuit may occur in either of two ways. 
There may be a short between different turns in one 
field coil or between the windings included in one coil. 
There may also be a short circuit between separate 
field coils. 

With the fields separated from all other connections 
as already explained, either the low or high voltage 
test lamp, an ammeter or a voltmeter may be used in 
testing for shorts as shown in Figure 53. 

The wiring diagram should be consulted in order to 
know how the field windings are connected and what 
windings are connected with each other. When it is 


DYNAMO TROUBLES 


141 


found that certain windings should be insulated, the 
test may be made. 

By using either the high or low voltage test lamp, 
a voltmeter or an ammeter, the test points should be 
connected to two coils that should be insulated from 
each other, the connection being generally made at 
the terminals or to the brushes. If the lamp lights 
or if the meter shows a flow of current or voltage, it 


Figure 52.—Test for Accidental Ground in Normally 

Grounded Field. 



indicates that the coils are shorted on each other. If 
the lamp remains out or if the meter shows no current 
or voltage, it shows that the coils are properly insu¬ 
lated. 

One test point should remain on one of the field coil 
terminals until the other test point is placed on each 
one of any other field coil terminals in the dynamo so 














142 


STARTING AND LIGHTING TROUBLES 


that each coil is tested for shorts on each of the others. 
Some machines have but one coil, some have one wind¬ 
ing divided between two or more coils while others 
have two or more windings in one cr more coils. 
These conditions may be found on inspection and by 
consulting the wiring diagrams. 

388. Fields Reversed or Dead. —If the dynamo 



Figure 53.—Test for Short Circuited Fields. 

runs, but does not generate and the brushes and com¬ 
mutator are known to be in good order, the fields may 
be dead or demagnetized. A certain amount of mag¬ 
netism, called residual magnetism, is supposed to 
always remain in the field magnet cores and pole 
pieces and it is this magnetism that starts the dynamo 
to generate when the armature is rotated. 

By accident, the residual magnetism may have been 




















DYNAMO TROUBLES 


143 


destroyed or reversed. With the battery charged and 
the connections correctly made, closing the cnt-out 
will then cause the dynamo to build up and generate. 
Closing the cut-out sends battery current around 



Figure 54.—Polarities of Field Cores. Upper Left; Two 
Salient Poles. Upper Right; Two Salient Poles and Two 
Consequent Poles. Lower Left; Four Salient Poles. Lower 
Right; Six Salient Poles. 


the field windings and magnetizes the cores of the 
windings. 

389. Reversed Fields. —If the dynamo has been 
taken apart or repaired, it may be that some of the 




























144 


STARTING AND RIGHTING TROUBLES 


internal connections have been wrongly made so that 
the field windings are reversed or so that some of the 
windings oppose the others. The correct polarities 
are shown in Figure 54 for two, four and six pole 
machines with both salient and consequent poles. It 
will be seen that each alternate pole piece or field 
should be of the same polarity. That is, the positive 
and negative poles should alternate around the ma¬ 
chine regardless of the polarities that may thus be 
brought on opposite sides of the armature. 

A test of this condition may be made by connecting 
the dynamo directly to a battery, or by simply closing 
the cut-out with the battery properly connected. The 
dynamo drive should be disconnected unless it con¬ 
tains an overrunning clutch. The dynamo will then 
run as a motor in the same direction that it should 
run when driven by the engine as a dynamo. 

Reversed fields may be located by testing with an 
ordinary pocket compass as shown in Figure 55. The 
compass should be brought carefully to the pole pieces 
or to a point on the dynamo housing that is in line 
with one of the field magnet cores. The compass 
should then be withdrawn well away from the machine 
and carefully brought back to the field adjacent to 
the first one touched. This field should be of a polarity 
opposite to the first one tested. If the compass is not 
taken well awav from the machine between tests, the 
polarity of its needle may be reversed and the test 
will be valueless. 

Fields which normally oppose each other while 
generating (such as those in reversed series machines) 
may be tested with the compass by allowing a small 
current from a dry cell or one cell of a storage battery 
to flow in the windings, then opening or short circuit- 


DYNAMO TROUBLES 


145 


ing one of the windings while the other is tested. The 
two windings should be of the same, rather than oppo¬ 
site polarity when tested in this way. The reason is 
illustrated in Figure 56 wherein it will be seen that 
current from dynamo to battery flows in opposite 
directions through the two windings, while that from 
battery to dynamo flows in the same direction. 



390. Loose Pole Pieces. —The magnet cores and 
the pole pieces must be securely fastened to the por¬ 
tion of the dynamo frame that carries them and the 
joint must be properly machined so that a good con¬ 
tact is maintained. 

Looseness or poor fitting at this point reduces the 
output of the machine because of the gap introduced 
into the magnetic circuit which reduces the number of 
lines of force flowing through the armature. 



146 


STARTING AND LIGHTING TROUBLES 




Figure 56.—Flow of Current Through Shunt and Series 
Fields While Generating and Motoring. Upper; Flow in 
Opposite Directions While Generating. Lower; Flow in 
Same Direction While Acting As Motor. 
































DYNAMO TROUBLES 


147 


If pole pieces are removed for any reason, they 
should be carefully marked so that they may be prop¬ 
erly replaced in the same position that they originally 
occupied. 


CHAPTER VH 


REGULATION TROUBLES 

400. Measurement of Output.—No adjustments 
should be made of regulating systems which directly 
control the amperage without an ammeter in the cir¬ 
cuit between dynamo and battery. 

No adjustment should be made of constant voltage 
systems without a voltmeter connected across the posi¬ 
tive and negative sides of the charging circuit, prefer¬ 
ably at the dynamo or brush terminals. 

401. Battery Charge.—No adjustment should be 
made of any system of output regulation without 
having the battery in a fully charged condition be¬ 
cause slight errors in setting made with a partially 
discharged battery may be greatly increased when 
the charge is complete. 

The battery should be charged to a point that causes 
a voltage across the dynamo brushes which is about 
one-fourth greater than the nominal voltage of the 
system. That is, with a 6 volt system, the voltage at 
the dynamo brushes should read about 7y 2 . 

The battery should show a specific gravity of 1.250 
or more when making these adjustments. If it is 
below this point a charge should be given before pro¬ 
ceeding with the work. 

402. Driving Conditions. —When possible, the 
output of the dynamo should be adjusted to suit the 


148 


REGULATION TROUBLES 


149 


driving conditions of the particular car being worked 
upon. 

For example: a car driven for short distances with 
a great many starts should have a high charge rate. 
Likewise, a car driven mostly at night or slowly, 
such as in city traffic, should have a high charge rate. 

A car driven a great deal in the country, or in the 
daytime, or on long trips without many stops and 
starts, should have a lower charge rate than the aver¬ 
age. 

403. Dynamo Temperature.—No system of regu¬ 
lation should be adjusted, or its adjustment changed, 
until the dynamo has been run long enough to warm 
up to its normal operating temperature, this usually 
requiring ten to twenty minutes running at fair speed. 

The output of a cold dynamo is greater than the 
output after the machine warms up, the difference 
usually amounting to ten or fifteen percent in amper¬ 
age. 

404. Dynamo Belt Drive.—In the case of a belt 
driven dynamo, the charging rate may be seriously 
affected by slippage, and before any changes are 
made in the regulation, the car should be taken on 
the road for a test. 

Unless the maximum charging rate is attained at, 
or below, a car speed of twenty-five to thirty miles 
an hour, it is quite probable that the belt is slipping 
and an examination should be made. Care should be 
used not to tighten the belt so much that the arma¬ 
ture shaft or cooling fan bearings will be damaged. 

The belt tension may be tested by closing the cut¬ 
out, either manual or electro-magnetic, while watch¬ 
ing the dynamo shaft or the fan. If either the dyna¬ 
mo or the fan make part of a revolution due to 


150 


STARTING AND LIGHTING TROUBLES 


the motoring effect in the dynamo, it would indicate 
a loose belt. 


410. THIRD BRUSH SYSTEM 


TROUBLES 

Commutator dirty, rough, 
pitted, etc. 

Field circuit open, fuse 
blown, etc. 

Regulating brush making 
poor contact, binding, 
loose, disconnected, too 
short, or wrong size or 
kind. Also, incorrect 
spring tension. 

Regulating brush in wrong 
position. 


REMEDY 

See “Commutator Troubles” 
(341, 342). 

See “Field Troubles” (381- 
384). 

See “Brush Troubles” (321- 
327). 


Make setting according to fol¬ 
lowing instructions. 


411. Battery Connection. —A third brush dynamo 
should not be operated unless a battery is in the 
circuit. Failure to observe this precaution will almost 
surely result in a burned out field winding or a burned 
out field fuse. 

412. Principle of Regulation. —The third brush 

is placed in contact with the commutator at a point 
between two of the main brushes and closer to one 
main brush than to the other. The difference in volt¬ 
age between the third brush and the main brushes de¬ 
pends on the distance between this regulating brush 
and the main brushes, the greater the distance, the 
greater the difference of voltage. Conversely, a reduc¬ 
tion of the distance between the brushes lowers the 
voltage. This is shown in Figure 57. 

The output of the dynamo depends on the voltage 
acting on the field winding and this voltage is deter- 


REGULATION TROUBLES 


351 


mined by the position of the third brush with refer¬ 
ence to the main brushes. 

413. Increasing the Output. —The voltage differ¬ 
ence acting on the field is that found between the 
third brush and the main brush farthest from the 
third brush and of opposite polarity. Therefore, 
moving the third brush farther from the main brush 



Figure 57.—Principle of Third Brush Regulation. 


already at the greatest distance from the third brush, 
or moving the third brush nearer the main brush 
already nearest the regulating brush, will increase the 
dynamo’s output. 

414. Decreasing the Output. —Moving the third 
brush nearer to the main brush from which it is far¬ 
thest removed to begin with; that is, toward a point 














152 


STARTING AND LIGHTING TROUBLES 


midway between the main brushes, will decrease the 
dynamo output. All of this is shown in Figure 58. 

415. Direction of Movement. —Should there be 
any doubt as to the direction of moving the third 
brush, a voltmeter may be attached with one of its 
leads on the third brush and the other on the main 
brush connected to the other end of the field as shown 

Decrease 


Increase 


Figure 58.—Direction of Movement of Third Brush. 

by the wiring diagram. If the other end of the field 
is grounded, the voltmeter should be placed between 
the third brush and the metal of the dynamo. The 
meter may also be connected between the third brush 
and the field as in Figure 59. 

With the voltmeter thus attached, moving the third 
brush so that the indicated voltage at a constant 
dynamo speed is increased, will increase the dynamo 
output. Moving the brush to decrease the voltage 
will decrease the dynamo output. The brush may 


















REGULATION' TROUBLES 


move either with or against the direction of armature 
rotation. 

416. Methods of Moving Brush. —Some dynamos 
are fitted with readily accessible means for changing 
the third brush position, others must be opened and 
the brush holder loosened and moved to a new posi¬ 
tion, while still others make no provision for altering 
the position. 



o o 


Figure 59.—Testing Third Brush Position With Voltmeter. 

The screw holes in the brush holder may often be 
filed out in one direction or the other to allow moving 
the holder to the desired position. 

If no other method is possible, one side of the third 
brush may be slightly filed away so that the end of 
the brush bearing on the commutator is made nar- 











154 


STARTING AND LIGHTING TROUBLES 


rower and is, in effect, moved one way or the other. 
This method is shown in Figure 60. 

Only a very'little filing should be done at one time, 
after which the brush should be replaced and the 
dynamo’s output tested with an ammeter in the charg¬ 
ing circuit. This method is not considered good prac¬ 
tice as it reduces the conducting capacity of the brush 
and causes a greater likelihood of brush trouble. 


Increase Decrease 




Figure 60.—Changing - the Adjustment of a Fixed Third 

Brush. 

417. A very little movement of the third brush 
will produce a decided change in the output of the 
dynamo. 

The third brush should not be moved so far that it 
makes contact with one of the main brushes. In some 
eases it may be necessary to move the main brushes 
to avoid this condition (-326). 

418. Re-fitting Third Brush. —After the brush 
position has been changed, the end of the brush should 
be fitted to the commutator as explained in section 
321. 

A loud singing noise at the third brush indicates 
that the contact with the commutator is poor, either 



REGULATION TROUBLES 


155 


because of a poorly fitted brush or a commutator in 
bad condition. 

SETTING THE THIRD BRUSH 

419. First see that the commutator is clean, 
smooth and properly undercut. 

Then see that the third brush is making good con¬ 
tact with the commutator. 

Test the battery and if it is undercharged, bring its 
gravity up to 1.250 or more. 

Connect an ammeter in series with the charging 
circuit between dynamo and battery. 

Run the dynamo until it reaches its normal operat¬ 
ing temperature. 

Refer to the section of wiring diagrams for the cor¬ 
rect charging rate of the type of system being handled. 

If the output is tco low, move the third brush away 
from the opposite main brush. (413) 

If the output is too high, move the third brush 
toward the opposite main brush. (414) 

The opposite main brush is of a polarity opposite 
to that of the third brush. 

After the third brush is re-set, fit it to the com¬ 
mutator with sandpaper. Be sure that the third brush 
is firmly secured in its new position. 

VIBRATING RELAY REGULATION 

420. Relays are so connected that they are 
operated either by the dynamo voltage or the charg¬ 
ing current and act to separate contacts on the relay. 
With the contacts separated, a resistance is inserted 
into the field circuit so that the field current is con¬ 
trolled. Vibrating relays are used in any of four 

. principal methods. 


STARTING AND LIGHTING TROUBLES 




Figure 61.—Typical Constant Current Regulators. 






























































REGULATION TROUBLES 


157 


421. Constant Current. — A vibrating relay is con¬ 
nected to allow the battery charging current to flow 
around its magnet. When this current reaches a pre- 



. Figure 62.—Typical Constant Voltage Regulators. 




















































































158 STARTING AND LIGHTING TROUBLES 

determined maximum (usually 10 amperes at 6 volts) 
the relay contacts open and insert a resistance in the 
field circuit. This prevents further increase in dy¬ 
namo output. Shown in Figure Gl. 

422. Constant Voltage. —A vibrating relay is con¬ 
nected across the dynamo brushes so that its magnet 
is acted upon by the dynamo voltage. When this 
voltage reaches the predetermined maximum (usually 



Figure 63.—Constant Current Regulator with Load Control. 

about one-fourth greater than the nominal voltage 
of the battery) the relay contacts separate and insert 
field resistance which prevents further increase of 
voltage. Shown in Figure 62. 

423. Load Control. —The constant current type of 
relay is sometimes wired so that part of its winding 
is weakened when current for the lamps is allowed to 
flow. This lamp current, while flowing, holds the 














REGULATION TROUBLES 


159 


dynamo output at a higher point than with the lamps 
turned off. Shown in Figure 03. 

Reversed Series Field. —The vibrating relay may 
be connected in such a way that when its contacts 
separate, current is forced through a reversed series 
winding on the dynamo fields, thus reducing or limit¬ 
ing the current output. Shown in Jesco wiring dia¬ 
grams. 

424. No Output From Dynamo. —This may be 

caused by any of the following vibrating relay 
troubles: 

Dirty contacts or bent contact arm (427). 

Loose or broken connections at relay terminals 
(428). 

Windings open circuited (432). 

Windings short circuited (432). 

425. Low Output From Dynamo. —This may be 
caused by any of the following vibrating relay 
troubles: 

Dirty contacts or bent contact arm (427). 

Loose or dirty connections at relay terminals 
(428). 

Spring tension too light (429). 

Air gap too great (430). 

Windings short circuited (432). 

Terminal connections reversed (433). 

426. High Output From Dynamo. —An output 
above normal may be caused by the following relay 
troubles: 

Bent contact arm (427). 

Spring tension too tight (429). 

Air gap too small (430). 

Windings short circuited (432). 

427. Dirty Contacts or Bent Arm. —If the con- 


160 


STARTING AND LIGHTING TROUBLES 


tact points are not clean, bright and smooth on their 
contacting surfaces, they should be cleaned or dressed 
by drawing a strip of very fine emery cloth or sand¬ 
paper between them while pressed lightly together. 
First place the rough side of the cloth or paper toward 
one contact, then toward the other^ 

The two contacts should meet over their entire sur¬ 
faces. If they are not in line with each other, the 
supports or arms should be bent to make them meet 
properly. 

428. Loose or Dirty Connections. —The terminal 

connections at the relay should be clean, free from 
dirt, oil or moisture, and should be securely fastened, 
inasmuch as any increase of resistance at this point 
may seriously affect the output of the dynamo. 

429. Spring Tension Adjustment. —The contacts 
are held together by means of a spring of any suitable 
form. The current or voltage acting on the relay 
magnet through its winding tends to pull the contacts 
apart against the spring tension. The greater the 
spring tension, the more current or voltage will be 
required to separate the contacts and insert the limit¬ 
ing resistance in the field circuit. 

Therefore, to increase the output of the dynamo, 
increase the spring tension; to decrease the output, 
lessen the spring tension. In some cases this tension 
is adjusted by a screw and locking device, while in 
other types no special adjustment is provided. In the 
latter case the spring tension may usually be changed 
by bending the support that carries either end of the 
spring. Do not stretch or shorten the spring itself. 
One condition of spring tension and air gap is shown 
in Figure 64. 

430. Air Gap Adjustment. —The movable contact 


REGULATION TROUBLES 


161 


is acted upon through an armature or keeper, that 
is, a piece of iron or steel carried at one end of the 
relay magnet. The air gap, or distance of this arma¬ 
ture from the end of the magnet core, alfects the cur¬ 
rent or voltage that is required to separate the con¬ 
tacts. 

The greater the air gap, the more current or voltage 
will be required and the greater will the dynamo out¬ 
put become. A smaller air gap will decrease the dy- 


Confacfa 


Bencf for 
spring fens/0/7 
afyusfmenf 




Figure. 64.—Cut-Out Adjustments. 


namo output. This air gap may be adjustable bv 
special means, or it may be necessary to bend some, 
of the parts to change the gap. 

Change of the spring tension is generally sufficient 
to secure the desired output, but in some cases it may 
also be necessary to change the air gap. 

431. Changing' the Output. —Do not change the 
adjustment of the vibrating relay until it is positively 
known that all other parts of the system are in good 
working order. 





















162 STARTING AND LIGHTING TROUBLES 

Test the battery, and if its gravity is below 1.250, 
have it charged before adjusting the relay. 

Connect an ammeter in series with the charging 
circuit between dynamo and battery or voltmeter 
across the dynamo brushes as in Figure 37. 

Refer to the section on wiring diagrams for the 
correct charging rate or voltage of the system being 
handled. 

If the output is too low, increase the spring tension 
or increase the air gap. 

If the output is too high, decrease the spring ten¬ 
sion or decrease the air gap. 

432. Windings Open or Short Circuited. —The 
internal connections of the regulator may be found 
from the wiring diagrams. Disconnect all outside 
wiring and connections or remove the relay from the 
dynamo or other part which carries it. 

With a test lamp, voltmeter or ammeter test for 
grounds between the magnet cores and other metal 
parts and the terminals of the windings, touching one 
test terminal to the metal while the other terminal is 
touched to each terminal in turn (115-117). 

Then test for short circuits between windings or 
parts that should be insulated. Touch one test point 
to any terminal while touching the other test point 
to each of the remaining terminals in turn (113, 114). 

Test for open circuits through each of the windings 
by touching one of the test points to one end of the 
winding, while the other test point is touched to the 
other end of the same winding (103-105). 

433. Terminal Connections Reversed.—If the 
contacts are found badly burned, or if there is spark¬ 
ing while they operate, it may indicate that the line 
from the dynamo field may be interchanged with the 


REGULATION TROUBLES 


163 


line from the dynamo brush (armature line). This 
reversal may occur either at the regulator or the dy¬ 
namo. The wiring diagram should be consulted. 

CENTRIFUGAL REGULATORS 

Regulation systems making use cf centrifugal 
force and used in rather large numbers include two 
principal types. 

440. Constant Speed. —In which a clutch driving 
the dynamo is acted upon by governor weights so 
that it is released above a certain speed, this speed 
being determined by the tension of the governor 
spring. The dynamo then operates at a constant 
speed and consequently at a constant voltage. This 
method has been used by Gray & Davis, Hartford, 
and Autolite. 

441. — Limited Amperage. —A contact arm ope¬ 
rated by a governor weight short circuits more or 
less of the winding on a spool of resistance wire, thus 
inserting or withdrawing resistance in series with 
the shunt field circuit of the dynamo. This system 
has been used by Delco. 

CONSTANT SPEED GOVERNORS 

442. In case the output is low, the shoes forming 
the clutch should be cleaned of any accumulations 
of grease or oil before making any change in the 
spring tension. 

It should also be ascertained that all other parts 
of the dynamo and charging system are in good 
working order. 

Test the battery, and if its gravity is below 1.250, 
have it charged. 


164 


STARTING AND LIGHTING TROUBLES 


Connect an ammeter in series with the charging 
circuit between dynamo and battery. 

Run the dynamo until it reaches its normal operat¬ 
ing temperature. 

Refer to the section of wiring diagrams for the 
correct charging rate of the equipment being 
handled. 

To increase the dynamo output, increase the spring 
tension; to decrease the output, decrease the spring- 
tension. 

After the adjustment is made, be sure that the set¬ 
ting is securely locked. 



Figure 65.—Centrifugal Governor. Gray & Davis Type C-l. 


443.—Gray & Davis, Type C-l. —The governor 
clutch consists of two flat, circular plates in contact 
and acted upon by two pivoted weights surrounding 
the coiled spring, as shown in Figure 65. - 

First loosen the set screw on the cross pieces car¬ 
ried by the armature shaft and supporting the two 
governor weights. 

Then insert two screwdrivers, one on each side of 















































































































REGULATION TROUBLES 


165 


the shaft, and just back of the cross piece support¬ 
ing the governor weights. Slightly compress the 
spring and tighten the set screw. Shortening the 
spring 1/16 inch increases the output about two am¬ 
peres. 

Gray & Davis, Type G-l and E. —The governor 
clutch consists of a cylindrical drum, inside of which 
are two shoes pressed into contact with the drum by 
coil springs, as shown in Figure 66. 



Figure 66.—Centrifugal Governor. Gray & Davis 
Types G-l and E. 


The adjusting screw is between the governor weights 
and is reached through holes in the drum and shoe. 
The slotted end of the adjusting screw is indicated 
by a notch in the shoe. The openings in tiic shoe and 
drum must be in line, when a 3/16 inch screwdriver 
may be inserted to the screw head. To increase the 
dynamo output, turn the screw to the right; to de¬ 
crease the output, turn the screw to the left. 

444. Autolite Governor.—Remove the plate on 
the end of the governor drum, then move the weights 
inward on the governor arms to increase the output, 

































































































166 STARTING AND LIGHTING TROUBLES 

or move them outward to decrease it. Move each 
weight the same distance and lock them securely in 
their new positions. 

445. Delco Governor. —The circuit of this type 
of regulation is shown in Figure 67. 

The following classes of trouble may be present: 
Poor contact of governor arm caused by dirty arm 
or spool; causes low output. 



Figure 67.—Principle of the Delco Centrifugal 
Field Rheostat. 


Wrong pressure on the governor arm bearing on the 
spool; causes low output. 

Short circuited resistance spool; causes high output. 

Open circuited resistance spool; prevents any 
output. 

Broken governor spring; causes low output. 

Wrong size wire on resistance spool; causes high 
or low output. 

446. Poor Coo tact .—A poor contact between the 





































REGULATION TROUBLES 


107 


arm and the spool will cause the armature to run at 
excessively high speed with the ignition button closed 
and will result in excessive clicking of the clutch when 
the engine is running at low speeds. 

If there is no contact between the arm and the 
spool, the shunt field current will have to pass through 
the entire length of the resistance wire and the cur¬ 
rent at low speeds will be almost zero. 

The spool should be cleaned occasionally because of 
oxidation caused by the slight sparking at the point 
of contact. This cleaning may be done with emery 
cloth. 

447. Wrong Pressure on Arm .—The contact arm 
should press on the spool with a tension of about 6 
ounces, but the pressure should not be enough to cause 
the arm to stick when raised by hand. Great care 
should be used in removing and replacing the re¬ 
sistance spool not to bend the arm and alter the 
tension. 

If the arm bears too hard, it will stick and reduce 
the charging rate. If it docs not bear hard enough, 
the contact will be poor, arcing will result and the 
resistance may eventually be burned out. 

If the contact is not good at all points of the arm s 
travel, the current with the arm in a poor contact 
position will drop to the minimum as determined by 
the full resistance of the spool. 

448. Resistance Short Circuited .—Should there 
be a short circuit such that the resistance is not in¬ 
cluded in the path between the dynamo shunt field 
and tjhe ground, in other words, should the shunt field 
be connected directly to ground and not through the 
resistance spool and arm; then there will be no regu¬ 
lation and a high charge rate will result. 


108 STARTING AND LIGHTING TROUBLES 

449. Resistance Open Circuited .—The resistance 
spool should be snapped into place between its holders 
so that there is a good contact. The holding springs 
should have sufficient tension to hold the spool firmly, 
for, if there is no contact between the shunt field 
winding and the resistance, and through the resistance 
to ground, there will be no current generated at any 
time. 


450. Resistance Spool Size .—Six different gages 
of nichrome resistance wire are used on the spools, 
these being as follows: 


SPOOL 


DIAMETER 

NUMBER 

GAGE 

AVIRE 

633 

21 

.028" 

703 

22 

.025" 

702 

23 

.022" 

701 

24 

.020" 

817 

25 

.017" 

955 

26 

.015" 


A spool of larger size wire, or lower gage number, 
slightly increases the maximum charging rate, but 
a higher rate is secured above the maximum point. 

Each spool has a wide cap at one end and a narrow 
cap at the other. By installing the spool with the 
wide cap at the bottom, the maximum charging rate 
is increased with a corresponding increase at higher 
speeds. 

The maximum charging rate is reached between 
18 and 25 miles an hour and should be between 16 
and 22 amperes. Above this speed, the amperage 
drops to between 10 and 15. 

451. Vesta.—Older models of Vesta generators of 
the permanent field magnet type, Avere fitted with 
a centrifugally controlled governor consisting of a 
rheostat resistance carried in series with the charg¬ 
ing circuit. 


REGULATION TROUBLES 


169 


At one end of the machine is a fly ball governor 
having two springs; one heavy and the other light. 
The light spring tension determines the time at which 
the rheostat arm completes the charging circuit, thus 
acting as a cut-out. The heavier spring determines 
the amount of resistance inserted at any given speed 
of the dynamo. Tightening this spring increases the 
output, while loosening its tension reduces the out¬ 
put. The connections are shown in the wiring dia¬ 
gram. 


OTHER REGULATING SYSTEMS 

In addition to the third brush, vibrating relay and 
centrifugal governor types which have already been 
considered, the following forms.are sometimes found. 

460. Compound Field Winding. —Used only in 
connection with a vibrating relay, speed governor or 
some additional form of control except in rare cases. 

461. Reversed Series Field. —In which the series 
winding of a compound field opposes the effect of the 
shunt and thereby limits the amperage. Has no parts 
except a field coil not included in the ordinary dy¬ 
namo, is not adjustable, and requires no attention as 
far as its regulating properties are concerned. 

462. Remy Thermostat Control, —Some of the 
third brush machines made by the Remy Electric 
Company have, in addition to the third brush, a ther¬ 
mostat which inserts or withdraws resistance in the 
shunt field circuit. The connections of this thermo¬ 
stat are shown in Figure 68. 

The thermostat is composed of a resistance unit 
together with two silver contact points, one of which 
is carried on a spring blade. The blade consists of 
a strip of spring brass welded to a strip of nickel 


170 


STARTING AND LIGHTING TROUBLES 


steel, a combination which bends under heat because 
of the greater expansion of the brass. 

The blade is permanently riveted to a bracket 
through insulating washers and the spring tension is 
such that it holds the two contacts together at low 
temperatures, but when the temperature in the dy- 




Figure 68.—Remy' Thermostat Control. 


namo case reaches approximately 175° Fahrenheit, 
the blade bends and separates the contacts. 

While the thermostat contacts are closed, full field 
current passes through them and allows a full output 
from the dvnamo. With the thermostat heated and 
the contacts separated, the output is reduced from the 
maximum of 18 to 20 amperes to 13 or 14 amperes. 

The thermostat resistance acts as a field fuse and 
will burn out in case of an open circuit between 


























REGULATION TROUBLES 


171 


dynamo and battery. The trouble should be located 
and a new unit installed. 

Should the dynamo give a normal output for the 
first few minutes after starting, and should the out¬ 
put then drop to zero, it indicates that the thermostat 
resistance is burned out or disconnected. Under such 
conditions there will be severe arcing at the contacts 
as the thermostat operates to open them. 

Later Remy systems make use of several thermostats 
operating at different temperatures. In this case, no 
other form of regulation is used with the thermostats. 



Figure 69.—Principle of Rushmore Iron Wire Control. 

463. Rushmore Iron Wire Control. —Bosch and 
Bosch-Rushmore systems, also the original Rushmore 
system, make use of a system of regulation known as 
iron wire control and shown in circuit by Figure 69 

The dynamo field windings include one of the usual 
shunt type and a second of the reversed series type 
which is called the bucking coil in these systems. 

In parallel with the reversed series winding is a 
coil of iron wire and, inasmuch as this iron wire 
has a resistance much below that of the reversed series 
winding, most of the charging current flows through 
the iron, which is called the ballast coil. 


























172 


STARTING AND LIGHTING TROUBLES 


When the current reaches a certain point, the iron 
wire has reached a heat just below dull red and it is 
a characteristic of iron to greatly increase its re¬ 
sistance at this critical temperature. 

The increased resistance of the iron then causes 
most of the charging current to flow through the re- 

MOTOR LEADS 



Figure 70.—Delco Ampere-Hour Meter Connections. 

versed series winding and to reduce the dynamo’s 
output. 

The dynamo’s maximum output is determined by 
the size of wire on the ballast coil, the larger the 
wire the greater the maximum output and the smaller 
the wire the less the maximum output. 

Each ballast coil contains a given length of wire 
and the gage number is stamped on the end. Sub¬ 
stituting a larger wire, or a lower gage number, in- 









































REGULATION TROUBLES ' 173 

creases the output; while substituting a smaller wire 
or larger gage number reduces the output. 

464. Delco Ampere-Hour Meter. —The earliest 
Delco systems incorporated a watt meter or an am¬ 
pere-hour meter in the charging systems and through 
this meter flowed all the current entering or leaving 
the battery. The connections are shown in Figure 70. 

As the large meter hand travels in the direction of 
charging, it finally reaches a point at which contacts 
are opened and a resistance is inserted in the field 
winding. Further travel of the hand will then open 
a second set of contacts and stop the charge by open¬ 
ing the shunt field circuit of the dynamo. 

This hand is held by a spline on its post and at 
intervals of about two weeks the hand should be lifted 
and turned about 20 points to the right or in the 
direction of discharge. This will cause the battery 
to receive the necessary additional charge in propor¬ 
tion to discharge. However, do not turn the hand past 
the number “70” on the dial. 

The charge rate of these dynamos may be altered 
by changing the small link, in appearance like an 
open fuse, which is connected between the upper left 
hand terminals of the multiple blade starting switch. 

Two links are used, either a single strand or a 
double strand. The single strand gives a low output, 
the double strand a high output. These links should 
never be replaced with copper wire, as this would 
allow an excessive charge rate. 

465. U. S. L. Carbon Regulator.— Discs of carbon 
are used for field resistance in the U. S. Ij. regulator 
shown in the wiring diagrams. The pressure on these 
discs is provided by an adjustable spring. With the 
discs pressed together there is little resistance in tin 1 


174 


STARTING AND LIGHTING TROUBLES 


field circuit and the output of the dynamo is high. 
The charging current flows through an electromagnet 
which attracts an armature that opposes the spring 
tension and releases the pressure on the discs. The 
minute gaps between the discs interpose resistance 
in the field circuit and the dynamo output is reduced. 

Increasing the spring tension increases the dynamo 
output, while decreasing the spring tension decreases 
the output. 



466. Bosch Carbon Regulator.—The Bosch con¬ 
stant voltage system, shown is Figure 71, uses a mass 
of mixed carbon and mica for field resistance. This 
mass is compressed by the tension of a spring and 
the spring tension is opposed by an electromagnet 
whose winding is connected across the dynamo 
brushes, being therefore acted upon by the dynamo 
voltage. 

The spring tension is adjustable by turning a screw 


































REGULATION TROUBLES 


175 


near the top of the regulator. Turning the screw in, 
increases the spring tension and increases the dynamo 
voltage and output. Turning the screw out, lessens 
the spring tension and lowers the dynamo voltage and 
output. 

467. Adlake. —The Adlake regulator is shoivn in 
the illustration, Figure 72. An arm, traveling 
over a rheostat resistance, is attached to a weight 



by means of a cord running over a pulley. The weight 
is moved by a solenoid coil through which passes the 
charging current. Increase of current draws the 
























176 


STARTING AND LIGHTING TROUBLES 


weight down and causes the arm to insert more and 
more of the resistance into the field circuit. The out¬ 
put is increased by adding weight (shot) to the 
plunger and is decreased by removing weight. 

468. Delco Constant Voltage Regulator.— The 

construction details are shown in Figure 73. The 
















































































REGULATION TROUBLES 177 

regulator consists of a tube of insulating material 
around which is a coil of resistance wire. The lower 
end of the tube and coil dips into a bath of mercury 
and the upper end is acted upon by a solenoid ener¬ 
gized by being connected across the dynamo brushes. 
The solenoid lifts the tube out of the mercury or 
allows it to dip to a greater or less extent according 
to the dynamo voltage. 

The resistance wire forms a part of the field circuit. 
That portion of the wire dipped into the mercury 
at any time is short circuited and the field resistance 
is cut down by a corresponding amount so that the 
dynamo output is determined by the voltage acting on 
the solenoid and tube. The voltage is changed either 
by a small lever on the regulator or by placing a 
connecting link of higher or lower resistance between 
the regulator and cut-out, a higher resistance causing 
an increased voltage. 

469. Aplco Carbon Disc Regulator. —This regu¬ 
lator, the connections for which are shown in the 
wiring diagram, consists of a series of carbon discs 
through which the field current passes. Pressure is 
applied to the discs by a spring whose tension is de¬ 
termined by an adjusting screw. The spring is op¬ 
posed by the action of a solenoid and plunger acted 
upon by the charging current. The output in amperes 
is increased by turning the screw up (increasing the 
tension) and is decreased by turning the screw down. 

470. Aplco Stop Charge Relay. —As shown in the 
wiring diagram, this system includes two relays in 
the controller housing. One is the cut-out and the 
other is connected across the charging circuit so that 
it is acted upon by the battery voltage. When the 
voltage of the battery reaches approximately 2 1/2 


178 


STARTING AND LIGHTING TROUBLES 


per cell, or 7 1/2 for the three cell units, the relay 
contacts separate and insert resistance in the dynamo 
field circuit, thus reducing the charge until the 
battery voltage falls. 

471. Dcaco Permanent Magnet Dynamo. —The 

dynamo is constructed with permanent magnet fields 
in combination with shunt and series field windings. 
Various combinations are effected by the opening and 
closing of relay contacts, the relay being actuated by 
the charging current. In the first position the shunt 
winding assists the permanent magnets; in the second 
position the shunt winding is opened and the per¬ 
manent magnets act alone; in the third position the 
shunt remains open and the series winding opposes 
the permanent magnets, but with a resistance in cir¬ 
cuit with the series field; and in the fourth position 
the series winding opposes the permanent magnets 
without the resistance in circuit and with the shunt 
open. 

472. Esterline Control.—Two forms of Ester¬ 
line dynamos are shown in the diagrams, one having 
two wires attached and the other having four wires. 
The two wire dynamo is constructed with permanent 
field magnets combined with a shunt and series wind¬ 
ing in addition. The four wire type has permanent 
magnets with a shunt and series winding, also a third 
winding through which current for the lamps passes 

The amperage is increased when the lamps are 
turned on, this effect being secured by the flow of 
lamp current around the field winding. 

473. Jesco 1913 System. —The system consists of 
a motor-dynamo having series, reversed series and 
shunt windings; also a controller unit containing the 
lighting and starting switches, the cut-out and the 


REGULATION TROUBLES 17;> 

regulator relay. The regulator acts to change the 
current through the fields by means of a resistance. 
Ihe battery charge is changed by moving a small 
handle found at the bottom of the controller unit. 
Moving this handle toward “HIGH” increases the 
charge rate, moving it toward “LOW” decreases the 
charge. 

474. Jesco 1914 and 1915 Systems. —The 1914 sys¬ 
tem includes a motor-dynamo with series, reversed 



Figure 74.—Wells Magnetic Shunt Control. 


series and shunt windings similar to the 1913 type. 
In this case, however, a vibrating relay controller is 
carried on the motor-dynamo housing. The charging 
current causes the relay contacts to open and leave 
the reverse series field winding in parallel with a high 
resistance. Current then flows through the reversed 
series winding and reduces the output. The regulator 
of the 1915 system is the same as that for 1914, but 
the motor and the dynamo are separate units con- 






ISO STARTING AND LIGHTING TROUBLES 

nected in tandem. The dynamo carries a shunt and 
a reversed field winding. 

475. Wells Magnetic Shunt Control. —The Wells 

lighting dynamo is of the two pole type with a field 
winding carried between the poles above the arma¬ 
ture. Between the poles and below the armature is 
a piece of soft iron so hinged that the magnetism of 
the pole pieces attracts this iron, as shown in Figure 
74. The attraction is resisted by a coiled spring. As 
the dynamo output and field strength increase, the 
iron is attracted and is drawn closer to the pole pieces. 



More of the magnetic lines of force then pass through 
the iron shunt, in place of through the armature; the 
armature current is thus reduced and the output of 
the dynamo maintained practically constant. 

476. Westinghouse Reversed Series System.— 
Early models of Westinghouse dynamos carried two 
field windings, one a shunt and the other a reversed 
series. All of the current passing to the battery for 
































REGULATION TROUBLES 


181 


( barging passes through the reversed series winding 
and thus controls the output in the usual way. With 
the lamps turned on, the current for lighting does 
not pass through the reversed series field, but is taken 
from the dynamo brush directly to the lighting lines. 
This reduced flow through the reversed series field 


Resistance 



allows an increased output from the dynamo with the 
lamps lighted. The principle is shown in Figure 75. 

477. Cam Regulator. —This system is of the con¬ 
stant voltage type. The principle is shown in Figure 
7(i. The regulator consists of two contacts which, 
when closed, short circuit a resistance which is other¬ 
wise inserted in the shunt field circuit. One of the 
contacts is acted upon by a cam attached to the 
dynamo armature shaft so that each time the shaft 






















182 


STARTING AND LIGHTING TROUBLES 


turns around, the contacts are brought together. The 
position of the other contact is determined by the 
pull of an electromagnet acted upon by the dynamo 
voltage. As the voltage increases, this second contact 
is drawn farther from the first one and the time dur¬ 
ing which the contacts are together is therefore de¬ 
creased. This allows the resistance to remain in the 
field circuit for a greater length of time and the dy¬ 
namo voltage falls. This action maintains the voltage 
very nearly at a constant value. 


CHAPTER VIII 


CUT-OUT TROUBLES 


500. ELECTROMAGNETIC TYPE 


TROUBLE 

SYMPTOM 

REMEDY 

Shorted, ground¬ 
ed, open cir¬ 
cuited or high 
resistance at. 
connections. 

Low output or 
no output. 

Clean contacts and ter¬ 
minals. Tighten 
joints and examine 
for troubles men¬ 
tioned. 

Sticking open or 
closed. 

No charge or dis¬ 
charge with 
engine idle. 

Clean contacts and 
moving parts. Ex¬ 
amine spring for 
breakage or loose¬ 
ness. 

Reversed con¬ 
nections. 

Fluctuating 

charge. 

Test connections or ex¬ 
amine wiring dia¬ 
gram. 

Windings open 
circuited. 

No charge. 

Make tests following. 

Not properly ad¬ 
justed. 

Not sufficient 
charge or ex¬ 
cessive drain 
on battery. 

Make adjustment as ex¬ 
plained in following 
instructions. 


501. Shorts, Grounds or Opens.— The contacts 
should be examined and if they are found dirty, rough 
or pitted they should be dressed by drawing a strip 
of very fine emery cloth or sand-paper between them, 
first with the rough side toward one contact, then with 
it toward the other. 


183 






















184 STARTING AND LIGHTING TROUBLES 

The contacts should meet squarely and over their 
entire face. If they do not do so, the supports hold¬ 
ing them should be bent to bring about this con¬ 
dition. 

If the cut-out parts are dust covered, especially if 
this unit is inside the dynamo, this accumulation 
should be blown or wiped away. 

The terminal connections must be tight and chan. 
Watch for corrosion, dirt, oil, moisture and loose wire 
strands. 

502. Sticking Open or Closed. —If the contacts 
have been badly burned or allowed to go too long 
without attention they may stick together and cause 
a discharge after the engine has stopped. Cleaning 
with emery cloth or sandpaper as described will pre¬ 
vent this trouble. 

Sticking open of the contacts can be caused by 
mechanical faults or by troubles in the windings 
which are considered later. Mechanical faults can 
be found by examination and they will suggest their 
own remedies. 

503. Reversed Connections. —If the positive and 
negative connections are reversed, either at the cut¬ 
out or at any point between cut-out and battery, it 
may cause a violent opening and closing of the cut¬ 
out contacts with a consequent fluctuation of the 
needle of an ammeter in the charging circuit. The 
trouble may be corrected by testing the polarity of the 
connections (126, 127) or by following the wiring 
diagram. 

With a great majority of dynamos, especially the 
newer types, reversal of the connections will simply 
cause the dynamo to reverse its polarity the first time 
the cut-out closes and without doing any harm. Some 


CUT-OUT TROUBLES 


185 


systems are constructed to obtain such a reversal at 
periodic intervals. 

WINDINGS OPEN CIRCUITED 

504. Shunt Winding Test— If the cut-out does 
not close, connect a voltmeter across the dynamo 
brushes. If the voltage is above that of the battery 
it probably indicates that the cut-out shunt is open 



Figure 77.—Circuits of Electro-Magnetic Cut-Out. 


circuited. Now close the contacts by hand. If they 
stay closed (due to the action of the series winding) 
it indicates that the shunt winding is open circuited 
and that the series winding is in good order. Typical 
circuits in an electro-magnetic cut-out are shown in 
Figure 77. 

With the aid of a wiring diagram, the shunt wind- 























186 STARTING AND LIGHTING TROUBLES 

ing may be tested for open curcuits in the usual man¬ 
ner by using a test lamp, an ammeter or a voltmeter. 

505. Series Winding Test. —With the engine run¬ 
ning and the cut-out closed, remove or disconnect the 
line from the cut-out contact to the battery. Then 
force the contacts apart and note the pressure re¬ 
quired. Then replace the line just removed and again 
force the contacts apart. If the series winding is in 
good order, the effort should be much greater with 
the wire in place than with it removed. 

If, when the line was disconnected in the foregoing 
test the contacts separate, it indicates that they were 
not in contact or that there is an open circuit. 

CUT-OUT NOT ADJUSTED 

506. All tests of the cut-out operation with a view 
to making a change in the adjustment should be made 
with a fully charged battery. Test the battery, and 
if its gravity is below 1.250, have it charged before 
proceeding. 

A discharged battery will allow the cut-out to close 
at a speed much lower than will a fully charged bat¬ 
tery. This difference may amount to as much as 
two or three miles an hour car speed, which shows the 
necessity for watching the battery condition. 

In order to properly adjust a cut-out it is necessary 
to connect a voltmeter across the dynamo brushes to 
read the voltage at closing, and to have an ammeter 
in the charging circuit to read the amperage of dis¬ 
charge when the cut-out opens. The connections are 
shown in Figure 78. 

507. Cut-out Closing. —The cut-out should close 

when the dvnamo voltage exceeds that of the battery 
by y 2 to 2 volts for a six volt system, or a propor- 


CUT-OUT TROUBLES 


187 


tionately greater voltage difference for higher voltage 
systems. That is, a six volt cut-out should close when 



Figure 78.—Ammeter and Voltmeter Connections for 

Cut-Cut Adjustment. 


the dynamo voltage is between 6y 2 and 8 volts, de¬ 
pending somewhat on the state of charge of the bat¬ 
tery. 



























188 


STARTING AND LIGHTING TROUBLES 


The time of cut-out closing is determined by the 
tension of the spring and by the gap between the 
end of the magnet and its armature. 

Earlier closing is secured by lessening the spring 
tension or by reducing the gap. 

Later closing is secured by increasing the spring 
tension or by increasing the gap. 

508, Cut-out Opening. —The cut-out should open 
at a discharge current of 0 to 2 amperes. The less 
the discharge when the cut-out opens, the better it is 
for the system, both because of the lessened drain on 
the battery and because of the decreased arcing at 
the contacts. 

The cut-out should open at a car speed about 2, 
miles an hour less than the speed at which it closes. 

The time of cut-out opening is determined by the 
spring tension, the gap being so small with the cut¬ 
out closed, that it does not affect the opening. 

Earlier opening (less discharge) is secured by in¬ 
creasing the spring tension. 

Later opening (greater discharge) is secured by 
decreasing the spring tension. 

509. Cut-out Adjustment.—With the voltmeter 
across the dynamo brushes and the ammeter in the 
charging line, the engine should be started and its 
speed gradually increased while the voltmeter is 
watched. The cut-out should close as soon as the 
dynamo voltage is above the nominal voltage of the 
battery by a small margin. It may, however, close 
with a low voltage or a high voltage. Either of these 
incorrect conditions should be noted. 

The ammeter should then be watched and the en¬ 
gine stopped. There should be a discharge current 
of 0 to 2 amperes when the cut-out opens. The open- 


CUT-OUT TROUBLES 


189 


ing may occur before the ammeter drops to zero or 
it may not occur until the discharge is more than 
2 amperes. Either of these wrong conditions should 
be noted. 

510. If the cut-out closing or opening is wrong, 
either the spring tension, the air gap or both, should 
be changed according to the following outline: 


VOLTAGE AS 

CUT-OUT CLOSES 

AMPERAGE AS 

CUT-OUT OPENS 

Correct (just 
above bat¬ 
tery volt¬ 
age) 

Still charg¬ 
ing 

More than 2 
ampere dis¬ 
charge 

Below voltage 
of battery 
(early clos¬ 
ing). 

Correct (0 to 2 
amperes 
discharge) j 

Still charging 

More than 2 
ampere dis¬ 
charge 

Too far above 
battery volt¬ 
age (late 
closing). 

Correct (0 to 

2 amperes 
discharge). 

Still charging 

More than 2 
ampere dis¬ 
charge 


CHANGE TO BE 

MADE IN SPRING 

TENSION 

CHANGE TO E 
MADE IN All 
GAP 

Decrease 

No change 

Increase 

No change 

No change 

Decrease 

Decrease 

Decrease 

Increase 

Decrease 

No change 

Decrease 

t 

Decrease 

Increase 

Increase 

Increase 


MANUAL CUT-OUT 

550. Some types of equipment do not use the 
electromagnetic cut-out, but substitute a hand oper¬ 
ated switch which is generally interconnected with 







































190 


STARTING AND LIGHTING TROUBLES 







































CUT-OUT TROUBLES 


191 


either the ignition or starting switch and in some 
cases with both ignition and starting. Such cut-outs 
have been used by Delco, Dyneto, Entz and others. 
Several forms are illustrated in Figure 79. 


REMEDIES 

Contact points should be 
cleaned with fine emery 
cloth and set to make full 
contact. 

Should be cleaned and tight¬ 
ened. 

A manual cut-out such as 
Dyneto and Entz, or a tour¬ 
ing switch such as U.S.L., 
should be open or on the 
neutral point when driving 
at very low speeds to pre¬ 
vent battery discharge. 
While on long daylight 
tours, this switch should be 
opened to prevent excessive 
charge. 

As soon as the manual switch is closed it makes con¬ 
nection between the dynamo and battery. Until the 
engine is started, and thereafter until the dynamo 
reaches a speed that generates a voltage aboye that 
of the battery; a discharge takes place from the 
battery through the dynamo armature and fields. 

With the Delco system, this discharge is used to 
rotate the motor-avnamo armature shaft and allow 
easy meshing of the starting gears. It will be noticed 
that the dynamo overrunning clutch will click con¬ 
tinually at very low speeds, indicating that current 
from the battery is driving the armature faster than 
the speed of the drive shaft from the 


Contacts dirty, burned or 
bent. 


Loose terminal connections. 


Used wrong. (Does not 
apply to manual cut-outs 
interconnected with igni¬ 
tion, such as Delco.) 


CHAPTER IX 


STARTING SYSTEM TROUBLES 

600. The troubles considered in this chapter affect 
the brushes, commutator, armature, field windings and 
housing of the motor and are the same kinds as listed 
under “Dynamo Troubles,” in Chapter VI, although 
their symptoms, the results and the remedies are usu¬ 
ally different. 

Some of the troubles may be found by examination, 
others by the action of the motor with the starting 
switch closed, while still others are located by tests 
for power and tests with the motor running free. 

It should first be ascertained that current at the 
proper voltage is reaching the motor. This may be 
done by removing the large cable attached to the 
motor and inserting a low voltage test lamp or a volt¬ 
meter between the cable end and the terminal from 
which it was removed. With the starting switch 
closed, the lamp should light or the meter indicate bat¬ 
tery voltage. If these indications are not present, the 
trouble is outside the motor, either in the switch or 
the connections to the battery. 

PRELIMINARY EXAMINATION OF THE MOTOR 

With the brush and commutator covers removed 
the following examination should be made: 

601. Brush Test. —With the starting switch 
closed, press lightly on each of the brushes and move 

192 




STARTING SYSTEM TROUBLES 


193 


them about with a rocking motion. Should this cause 
the motor to operate, it indicates brush trouble as 
follows: 

Making poor contact on commutator. 

Spring pressure too light. 

Binding or loose holders. 

Brushes worn out, too short. 

602. Commutator. — The commutator surface 
should be examined for the following: 

Dirty or blackened. 

Mica flush with, or above copper bars when carbon 
brushes are used. 

Rough, grooved or pitted. 

Loose, high or low segments. 

If only one point on the commutator is burned, it 
probably indicates that one or more armature coils 
attached near this point are burned out or otherwise 
open circuited. 

603. Armature. —The armature should be moved 
up and down, also endwise, by hand in order to locate 
loose bearings or excessive end play. Starting motors 
are generally provided with plain bearings or bush¬ 
ings and these will have to be replaced with new ones. 

604. Housing. —The interior of the motor must 
be kept free from excessive collections of dirt, oil or 
moisture. Dirt and dust may be blown out under air 
pressure and oil may be wiped away with a cloth 
slightly moistened with kerosene. Do not use gasoline. 

If the interior of the motor has become thoroughly 
wet so that it does not readily dry out with the covers 
removed, the machine should be removed from the car, 
all covers taken off, and the motor baked for about 
24 hours at a temperature between 200° and 230° 
Fahrenheit. 


1<) 1 STARTING AND LIGHTING TROUBLES 

605. Sparking at Brushes.—The motor should be 
run with the brush and commutator covers removed 
and the point of contact between brushes and com¬ 
mutator watched. Excessive sparking may indicate 
any of the following. 

Brushes making poor contact. 

Brush holders binding or loose 

Spring tension too light. 

Spring tension too heavy. 

Brushes worn too short. 

Brush position wrong after repairing. 

Commutator blackened or dirty. 

Commutator rough, pitted or grooved. 

Mica flush with, or above, copper on commutator. 

Armature open circuited. 

Armature short circuited. 

606. No Cranking.—Should the motor armature 
fail to revolve with the starting switch closed it may 
indicate any of the following troubles: 

Brushes binding or loose in holders. 

Brush circuit open, pig tails off. 

Brushes worn out, too short. 

Commutator dirty or blackened. 

Armature short circuited or grounded. 

Armature open circuited at two points on opposite 
sides. 

Field circuit open. 

Field short circuited or grounded. 

Field connected wrong. 

607. Slow Cranking.—If the motor cranks the 
engine very slowly, or if it starts to crank and then 
stops, any of the following troubles may be indicated : 

, Brushes making poor contact. 

Brushes worn short. 


STARTING SYSTEM TROUBLES 


195 


Commutator dirty, rough or grooved. 

Armature short circuited or grounded. 

Field short circuited or grounded. 

High resistance in field circuit. 

Field connected wrong. 

608. Fluctuating Starting Current. — A high 
reading ammeter may be connected in series between 
battery and motor and the starting switch closed. If 
the needle fluctuates as the motor armature revolves, 
it may indicate any of the following troubles: 

Poor brush contacts on commutator. 

Brushes binding or loose. 

Commutator dirty, rough, pitted or grooved. 

Mica above copper segments of commutator. 

Armature grounded or short circuited. 

Armature open circuited. 

Armature bearings loose. 

Armature has excessive end play. 

TEST WITH MOTOR RUNNING FREE 

609. If the motor drive can be temporarily dis¬ 
connected and an ammeter reading up to 50 amperes 
connected in series between the battery and motor, the 
amperage required for running the motor without 
load may be noted. Most motors will draw from 25 
to 40 amperes in this test provided a six volt system 
is being handled. Higher voltage systems will require 
a lower amperage in inverse ratio to the voltage. 

If the amperage is excessive it may indicate tight 
bearings or a short circuited armature or field. 

If the speed of the motor is very low it may indi¬ 
cate loose connections, a dirty commutator, poor brush 
contact or high resistance in the armature. 


196 


STARTING AND LIGHTING TROUBLES 



1 




Pa/i 

Figure 80.—Method of Making Power Test on Starting Motor. 































STARTING SYSTEM TROUBLES 


197 


If the motor runs at an excessively high speed it 
may indicate a short circuited field winding. 

POWER TEST 

610. It requires a certain turning effort to crank 
an engine and this effort is measured in foot pounds 
torque. One foot pound torque is the power which 
exerts a force of one pound at a distance of one 
foot measured away from a shaft. 

It requires from three to five times the torque or 
power to start an engine from rest as is required to 
keep it in motion at the cranking speed after once in 
motion. 

The approximate torque, measured in foot pounds, 
required to crank engines of usual construction is 
given in Table YII for the various bores and strokes. 
The heavy face figures give the starting torque and 
the light face figures the running torque. 

The torque exerted by a starting motor may be 
tested according to the following instructions and, by 
noting whether it is more or less than the require¬ 
ments as shown in the Table, it may be judged 
whether the motor is able to do its work on the car. 

The starting motor should be connected as shown 
in Figure 80. On its shaft should be placed a flanged 
pulley of any convenient radius and a cable with a 
spring balance at one end should be used to pass 
around the pulley. 

It will be evident that pulling on the ceble, that is, 
tightening it around the pulley, will place a load on 
the motor and this load may be measured in foot 
pounds. 

The battery used in this test should show a gravity 
reading of at least 1.250 or else the speed of the 


108 


STARTING AND LIGHTING TROUBLES 


motor will be low. The speed may be known by using 
an indicator on the end of the motor armature shaft. 

The reduction found in the gearing between motor 
armature shaft and the engine crank shaft should 
be known or may be calculated by counting the teeth 
on the gears and dividing. An engine should be 
cranked at a speed between 60 and 100 revolutions 
per minute for good starting. Therefore the desired 
cranking speed should be multipied by ti e gear reduc¬ 
tion to find the speed at which the motor armature 
shaft must revolve. 

The number of foot pounds required may be found 
from Table VII in the light faced figures for the size 
engine on the car. The required foot pounds should 
be divided by the gear reduction and this number 
should be multiplied by 12 to change it to inch pounds. 
The result should be divided by the radius (distance 
from center to outer face) of the pulley used. This 
final figure gives the reading on the spring balance 
that should be produced by pulling on the cord. 

With the cord pulled to give the required scale 
reading, the s^eed of the starting motor should be 
noted. If it is not equal to, or above, the speed at 
which the motor must revolve, the cranking operation 
will not be properly performed. 

The cord should then be pulled tighter and tighter 
until the motor stops. At this instant take the scale 
reading, then immediately release the cord to avoid 
burning out the motor. 

This final scale reading should be multiplied by the 
pulley’s radius, this result should be divided by 12 
to find the foot pounds at the motor shaft, and that 
result multiplied by the gear reduction to find the 
maximum torque that the motor is able to exert. If 



STARTING SYSTEM TROUBLES 


199 


this maximum torque is not equal to the figure given 
in heavy face type in Table VII, then the motor will 
have difficulty in starting the engine from rest. 

611 . MOTOR BRUSH TROUBLES 

TROUBLE REMEDY 


Poor contact with commu¬ 
tator. 

Binding or loose in holder 
or holder binding. 

Spring tension too light. 
Spring tension too great. 
Spring broken or loose. 

Circuit open. Pig tail broken 
or disconnected. 

Worn out. Too short. Holder 
touching commutator. 


Position wrong. May occur 
after repairs have been 
made. 


Wrong size or kind. 


Pit with sandpaper as direct¬ 
ed in section on dynamos 
(321). 

Fit with fine file. Clean and 
set holder. See section on 
dynamos (322). 

Test tension with scale and 
adjust spring. See section 
on dynamos (323). 

Clean and tighten fastenings 
or solder the connection 
(324). 

Replace with new brushes 
and fit them with sand¬ 
paper. See section on dy¬ 
namos (325). 

If excessive sparking takes 
place, brushes may be 
shifted not to exceed Vi- 
inch in direction opposite 
to commutator rotation. 

See section on dynamos 
(326). 

Obtain correct brushes from 
maker of motor or from re¬ 
liable supply house (327). 


612 . MOTOR COMMUTATOR TROUBLES 
The troubles considered here as those of the com¬ 
mutator are of a mechanical nature. Electrical trou¬ 
bles are considered as armature troubles and are so 
treated, inasmuch as the commutator is considered 
as one electrical unit with the armature. 


200 


STARTING AND LIGHTING TROUBLES 


TROUBLE 

Dirty or blackened. Clean 
once a year. 

Rough, pitted or grooved. 

High mica. 

/ 

Loose, high or low bar. 


REMEDY 

Clean with cloth or sand¬ 
paper. See section on dy¬ 
namos (341). 

Take off small cut in lathe, 
then undercut and dress 
surface. See section on dy¬ 
namos (342). 

If carbon brushes are used, 
undercut the mica as di¬ 
rected in section on dyna¬ 
mos (343). If copper 
brushes are used, it should 
not be necessary to under¬ 
cut the mica because these 
brushes wear it down. 

Remove armature and inspect 
fastenings. See section on 
dynamos (345). 


613 . MOTOR ARMATURE TROUBLES 

It should be borne in mind that in case of electrical 
trouble, the commutator is considered to be a part 
of the armature. 


TROUBLE 

Grounded armature or com¬ 
mutator. 

Open circuit in armature or 
commutator leads. Causes 
excessive sparking. 

Short circuit in armature 
or commutator. Will cause 
heating or smoke. 

Loose bearings or end play 
in armature shaft. 


REMEDY 

Make tests given in section on 
dynamos (361). 

Make tests given in section on 
dynamos (362, 363). 


Make tests given in section on 
dynamos (362, 364). 

Plain bearings of motor 
should .be replaced with 
new ones if found to be 
worn. Wick oiler openings 
should be at one side of the 
bearin". not at top or bot¬ 
tom (365). 


STARTING SYSTEM TROUBLES 


201 


614 . MOTOR FIELD TROUBLES 


TROUBLE 


REMEDY 


Open circuited field. Examine exposed leads and 

brush connections. Make 
test outlined in section on 
dynamos (381, 384). 

High resistance in field. Make test given in section on 

dynamos (381, 385). 

Grounded field circuit. Make test given in section on 

dynamos (381, 386). 

Short circuit within one coilMake test given in section on 
or between coils. dynamos (381, 387). 

Fields revei sed. Make compass test as ex¬ 

plained in section on dyna¬ 
mos (381, 389). 

Pole pieces loose or poorly Examine as explained in sec- 
machined. tion on dynamos (390). 


It should be borne in mind that all separate starting 
motors are series wound, that is, the battery current 
flows through the fields, brushes and armature as one 
single circuit. Internal wiring diagrams of repre¬ 
sentative starting motors are shown in Figure 81. 

In replacing old field coils with new, compare them 
carefully as to the method and position at which the 
leads are brought out and connected. These connec¬ 
tions determine the direction of the motor’s rotation. 

STARTING SWITCH TROUBLE 

650 . Starting switch troubles may be classified 
under two heads; first, those which cause open cir¬ 
cuits or high resistance, and second, those which cause 
short circuits or grounds. 

The above mentioned troubles are electrical. The 
switch is also subject to mechanical troubles which 


202 STARTING AND LIGHTING TROUBLES 

may or may not give rise to electrical defects. Me¬ 
chanical failures are generally apparent upon exami¬ 
nation and are easily remedied. 



Figure 81.—Typical Internal Connections of 
Starting Motors. 












STARTING SYSTEM TROUBLES 


203 


OPEN OR HIGH RESISTANCE IN SWITCH 


TROUBLE 


REMEDY 


■Contacts dirty or burned. 

Contact blades bent or 
jammed. 

Internal connections loose. 
Terminals dirty or loose. 
Wrong wiring connections. 


Clean with emery cloth or re¬ 
place if too short. 

Straighten to allow correct 
contact. 

Should be cleaned and secure¬ 
ly fastened. 

Should be cleaned and secure¬ 
ly fastened. 

Follow wiring diagram. 




652. Test for Open Circuit— Connect a voltmeter 
or a low voltage lamp between the terminals of the 
starting switch; or, with a grounded type of switch, 
connect between the battery lead terminal and the 
metal to which the switch is fastened. Figure 82, left. 






















204 STARTING AND LIGHTING TROUBLES 

With the starting switch closed, the voltmeter read¬ 
ing should drop nearly to zero or the lamp should 
go out or burn very dimly. If the voltmeter indicates 
voltage almost as high as the battery or if the lamp 
lights brightly, either an open circuit or high re¬ 
sistance in the switch is indicated. 


SHORT OR GROUND IN SWITCH 

TROUBLE REMEDY 

Contacts dirty, oily or wet. Clean with cloth or emery 


Contact blades bent or 
jammed. 

Switch housing wet or dirty, 
inside or outside. 

Switch remains closed, 
broken spring. 

Terminals loose or have 
loose wire strands. 

Terminals shorted. 

Internal connections loose. 


cloth. 

Straighten to prevent wrong 
contact. 

Clean with dry cloth or brush. 
Do not use gasoline. 

Clean sliding members and 
replace spring if found 
broken. 

Clean and tighten. Tape and 
shellac over any loose 
strands. 

Clean parts and make sure of 
unbroken insulation. 

Should be cleaned and se¬ 
curely fastened. 


654. Test for Short Circuit or Ground. —Discon¬ 
nect the battery cable from the starting switch ter¬ 
minal and insert a voltmeter or a low voltage test 
lamp between the cable end and the terminal. 

With the switch open, the voltmeter should show 
no reading or the lamp should remain out. If the 
voltmeter indicates pressure or if the lamp lights 
with the switch in its open position, it indicates a 
short circuit or ground. Figure 82, right. 


STARTING SYSTEM TROUBLES 


205 


STARTING SWITCH TYPES 

Starting switches may be classified under each of 
four headings as follows: 

655. Method of com- One side grounded, one wire type, 
pleting the cir- Both sides insulated, two wire type, 
cuit. 

Single pole, breaking only one side of 
the electrical circuit. 

Double pole, breaking both positive 
and negative sides of the circuit. 

656. Type of contact One set of contacts which are either 

points. open or closed. This includes V- 

shaped, ring or crown shaped, slid-, 
ing ring, spring blade, knife blade 
and motor brush switches. 

Two sets of contacts, only one of 
which is completed at any one 
time. This includes switches having 
starting resistance, those having 
contacts which open the charging 
circuit while the starting circuit is 
made and those causing the dynamo 
to run as a motor while the gears 
are meshed. 

657. Method of clos- Manual operation from a foot button 

ing. or hand lever. 

Spring released, in which a spring is 
first compressed should the gears 
fail to mesh. 

Magnetically released, in which a but¬ 
ton is pressed to energize a solenoid 
which in turn releases the starting 
* switch. 

Magnetically operated, in which a but¬ 
ton is pressed to energize a solenoid 
which in turn closes the main start¬ 
ing switch. 


2(X» 


STARTING AND LIGHTING TROUBLES 


658. Voltage. Single voltage systems in which but 

one voltage is used for both charg¬ 
ing and starting. 

Double voltage systems in which a 
higher voltage is used for starting 
than is employed for charging. This 
class includes knife, drum, sliding 
contact and V contact switches. 

The type of switch should be considered when lo¬ 
cating and remedying either electrical or mechanical 
trouble. Connections are shown in the wiring dia¬ 
grams. 

DRIVE TROUBLE 

680. Drive troubles are of a mechanical nature 
and are generally due to lack of lubrication, to in¬ 
correct lubrication, to misuse or neglect. 

In looking for the cause of trouble it is necessary 
to consider the kind of connection between the motor 
or dynamo and the engine, the method of shifting 
gearing into its operating position and any overrun¬ 
ning clutches that may be used. 

Kinds of connections include the following: 

Direct, on flywheel. 

Silent chain. 

Roller chain. 

Jointed shaft. 

Pump or timing gear shaft. 

Single reduction spur gear. 

Double reduction spur gear. 

Worm gear. 

Planetary with changing ratio. 

Planetary with constant ratio. 

Internal gear. 

Shaft and chain. 


STARTING SYSTEM TROUBLES 2</J 

Spur gear and chain. 

Worm gear and chain. 

Planetary gear and chain. 

Internal gear and spur gear. 

Worm gear and spur gear. 

Pinion shifts j include the following: 

Sliding gear, manually operated. 

Sliding gear connected to clutch. 

Screw shift, single reduction. 

Screw shift, double reduction. 

Magnetic or solenoid shift of armature shaft. 

681. Chain Drive. —Any drive employing a chain 
generally provides an adjustment for the slack due 
to wear. This adjustment should be set to allow about 



V 2 to % inch up and down play at the center of the 
chain between the sprockets. A tighter setting than 
this causes a humming noise, while a looser adjust¬ 
ment allows threshing. 

682. Screw Pinion Shift. —This class includes 
Bendix, Bijur and Westinghouse types. The general 
construction is shown in Figure 83. 









































208 


STARTING AND LIGHTING TROUBLES 


In the exposed types, the screw shaft and gear 
should be kept clean, but never lubricated. 

If the pinion fails to mesh with the starting motor 
running, it may be released by lightly tapping with 
a. hammer. 

If the pinion sticks in engagement with the fly¬ 
wheel teeth, it may be released by engaging high 
speed, and with the clutch engaged, moving the car 



Figure 84.—Parts of Overrunning Clutch. 


forward or backward. This indicates wrong align¬ 
ment or binding of the starter drive. 

A twisted or broken spiral spring indicates that a 
kick-back occurred while cranking and the ignition 
timing should be examined. 

683. Overrunning Clutch. —If an overrunning 
clutch sticks, it may generally be freed by tapping 
lightly but sharply with a hammer. If this fails, the 
clutch may be heated to soften any congealed lubri¬ 
cant. Such trouble indicates that the clutch needs 
cleaning, lubricating, or both. 

A Delco overruning clutch is shown in Figure 84. 

If the overrunning clutch locks in the wrong direc- 
















































































STARTING SYSTEM TROUBLES 


209 


tion it indicates that the center has been installed the 
wrong way around. 

If the clutch turns hard in both directions it may 
indicate that either of the races are damaged or that 
the rollers are wedged between the races. Such wedg¬ 
ing may result from the rollers sinking into slight 
depressions in the center piece. These depressions 
may be removed with an oilstone. 

If the clutch turns freely in both directions, that 
is, if it fails to lock, it indicates that the springs 
are broken or have lost their tension, or else that the 
plungers are sticking in the sockets, possibly from lack 
of lubricant. • 

If the clutch clicks and rattles when overrunning 
it indicates that the outer race has become roughened 
or ribbed and should be replaced. 


CHAPTER X 
BATTERY TROUBLE 

700. Battery trouble may result from lack of 
care, improper care, wrong mounting, wrong connec¬ 
tions or wrong conditions, mostly mechanical, of the 
battery itself. Trouble may also result from improper 
charge or discharge and from poorly performed re¬ 
pair work. 

Care of the battery includes keeping the electrolyte 
at the proper height and of the necessary purity, keep¬ 
ing the battery clean, keeping it charged and avoid¬ 
ing damage in rough handling. 

The information given in this chapter is neces¬ 
sarily somewhat condensed in form, but it has been 
made sufficient in scope to cover the needs of the 
electrical repair man as far as he is concerned with 
the storage battery. Inasmuch as battery service is 
a field is itself, those desiring to go more fully into 
that work should secure some complete book, such as 
the companion volume, “ Automobile Battery Care and 
Repair/’ which covers the construction, action, care 
and repair of these units. 

ELECTROLYTE 

701. If the electrolyte is found at a low level it 
may be due to any of the following reasons. 

Water not added (703). 

Electrolyte replaced in *wrong cell (705). 

Battery has been dropped (717). 

210 


BATTERY TROUBLE 


211 


Battery loose in carrier (730). 

Battery overheated (759, 760). 

High charge rate, Chart O (772). 

Excessive overcharge (774). 

Battery capacity too small (776). 

702. The level of the electrolyte should be main¬ 
tained at a point from % to % of an inch above the 
tops of the plates. This is done by adding distilled 
water once every week or ten days in warm weather 
and twice a month in cold weather. 

A low level of the electrolyte may have resulted 
in any of the following conditions: 

Sulphated plates. 

Buckled plates. 

Damaged insulators. 

Excessive deposit of sediment. 

Reversed negatives. 

Hardened negatives. 

703. Water should be added to each cell once 
each week or ten days in warm weather and twice a 
month in cold weather to bring the level of the elec¬ 
trolyte % to % inch above the plates. If the bat¬ 
tery is used a great deal or if other conditions are 
severe, an inspection should be made by removing the 
vent plugs more often than mentioned aboye. 

704. While it is necessary to keep the electrolyte 
level above the tops of the plates, the cells should not 
be filled too full. There is usually a well of some 
form inside the filler opening and the liquid level 
should generally be up to the lower edge of this well, 
but not above this point. An excess of electrolyte 
will be forced out of the cells by the gassing present 
in a charged battery or by a rise in temperature of 
the liquid with the resulting expansion. 


212 


STARTING AND LIGHTING TROUBLES 


705. The electrolyte drawn np into the hy¬ 
drometer syringe for testing the specific gravity 
should always be returned to the same cell from which 
taken. Failure to observe this precaution may lead 
to low gravity in one cell with high gravity in another 
because of the unbalanced amount of acid and water 
that results. Sulphated plates or damaged insulators 
may also result from this fault. 

706. It is best to use clean distilled water for 
making additions to the battery cells. In some cases 
the city water may be sufficient purity for this pur¬ 
pose, but a sample should first be submitted to some 
battery manufacturer for analysis and report. 

707. Water or electrolyte that is dirty or that 
contains chemical impurities, when added to the bat¬ 
tery, may cause damage to the insulators, corrosion 
of the grids or reversal of the negatives. 

708. Unless the liquid has been spilled from the 
battery, nothing but water should ever be added to 
the cells. The addition of electrolyte or of raw acid 
to increase the specific gravity will result in sulphated 
plates, buckled plates, damaged insulators, excessive 
sediment or corrosion of the grids. This, of course, 
does not apply to adjusting done in a battery station. 

709. Under no conditions should alcohol or any 
other kind of anti-freeze mixture be added to the 
battery cells. A battery properly charged will not 
freeze at any temperatures likely to be encountered. 

CLEANING THE BATTERY 

710. The battery top should be washed clean 
with water to which has been added a little ammonia 
or washing soda to neutralize any acid that may be 
present. This should be followed with pure water. 


BATTERY TROUBLE 


213 


A clean cloth should then be used to wipe the battery 
dry. 

711. Any grease or oil that has been deposited 
on the battery top or on* the case should be removed 
with gasoline if necessary, taking great care that no 
gasoline gets into the cells through the filler openings. 
The vent plugs should be in place as many of them are 
designed to prevent impurities from reaching the cells. 

712. If the battery top is found wet it may be 
due to any of the following reasons: 

Overfilling (704). 

Spilled electrolyte (713). 

Battery loose in carrier (730). 

Vent plugs loose or cracked (756). 

Defective sealing (758). 

713. While adding water to the cells, care should 
be exercised not to spill either water or electrolyte 
on the battery top as this moisture may form a slight 
short circuit or maj^ lead to corroded terminals and 
a rotted case. 

714. If the terminals are found to be dirty or 
corroded, they should be taken apart and thoroughly 
cleaned with a solution of washing soda and water 
and with a wire brush. When clean, the connections 
should be tightened and covered with vaseline. 

715. The terminals may have become corroded 
because of any of the following reasons: 

Overfilling (704). 

Spilled electrolyte (713). 

Battery loose in carrier (730). 

Copper wires attached at terminals (742). 

Vent plugs loose or cracked (756). 

Defective sealing (758). 

Flux used in lead burning (787). 


214 


STARTING AND LIGHTING TROUBLES 


GENERAL CARE 

716. A battery must be handled with care while 
removing it from the car and while it is off the car. 
The terminals and connecting bars should not be used 
for lifting. 

717. If the battery has been dropped from even a 
little distance, it is quite probable that one or more 
of the jars have been broken or that there has been 
internal breakage of the plates or connecting straps. 

718. If the terminals or their connections are 
found loose, they should be cleaned with washing 
soda or ammonia and water used with a stiff wire 
brush. The fastenings are then tightened and locked 
securely. Burned on terminals that have become 
loose should be refitted securely and a good job of 
burning performed. 

719. Should the battery be stored off the car for 
any length of time, it should be given a charge at 
least once in two months. This charge should be at 
the finishing or 24 hour rate and should be continued 
until both the specific gravity and voltage reach their 
maximum. The electrolyte level should be brought up 
to the proper point (701) by adding distilled water 
at this time. 

720. Allowing a battery to stand idle without 
periodic vcharge as just explained, whether the bat¬ 
tery is on or off the car, may result in buckled plates, 
excessive deposit of sediment, frozen electrolyte, cor¬ 
roded grids or hardened negatives. 

721. If the specific gravity of the battery has 
been low for a long time and without a proper charge, 
serious damage has probably resulted. The gravity 
should never be allowed to remain much below 1 20(' 
for any length of time. 


BATTERY TROUBLE 


215 


BATTERY MOUNTING 

730. The battery must be securely held in its box 
or carrying frame. Clamps that catch over the han¬ 
dles or on special fasteners attached to the battery 
case should be used at all times. The battery must 
not be free to jump about with the car in motion. A 
loose battery will probably result in broken jars or 
broken posts and connectors. 

731. The battery should be so mounted as to keep 
out water, oil and dirt. A cover, cleat or bar that 
presses down on the terminals, posts cr cell covers 
should not be used. 

732. The battery compartment should be ven¬ 
tilated and drained. The battery should have free 
air space on all sides and should rest on cleats or 
cross pieces rather than on a solid bottom. 

733. The cables attached to the battery should 
be long enough to avoid any danger of puffing or 
strain on their fastenings or on the battery posts. A 
slight amount of weaving may take place with the 
car in motion and this movement should be allowed 
for in the cable slackness. 

4 

BATTERY CONNECTIONS 

740. All of the battery connections at the large 
cables should be clean and tight because any loose¬ 
ness or dirt will offer serious resistance to the heavy 
flow of current at a low voltage that is required in 
starting. 

741. The connection between one of the battery 
cables and the metal framework of the car should be 
clean and tight when the system is of the one wire or 
grounded type. This connection should be made by 
scraping a spot on the metal until it is clean and 


216 


STARTING AND LIGHTING TROUBLES 


free from any traces of paint or grease. The cable 
end should be likewise thoroughly cleaned and the 
two parts held in close contact by secure bolting. The 
joint should then be covered with vaseline or shellac. 

742. No copper or brass wires should be attached 
ait the battery terminals or to the large cables within 
four or five inches of the battery. The acid fumes 
or the moisture which contains traces of acid will 
corrode these wires and cause high resistances. 

743. The positive terminal of the battery should 
be led to the positive terminal of the dynamo, the 
negative of the battery to the negative of the dynamo. 
In case one side of the battery is grounded, the po¬ 
larity of the grounded side must be the same as the 
polarity of the grounded side of the dynamo. The 
polarity of wires may be tested as explained in sec¬ 
tions 126 and 127. 

744. In case the equipment includes a commutat¬ 
ing switch for changing the voltage during charge 
and discharge, the charge to each section of the 
battery, also the discharge from each section should 
be tested separately. Trouble in one or more contacts 
of this type of switch may lead to uneven charge or 
discharge, causing trouble in one section of the bat¬ 
tery. 

GENERAL CONDITION OF BATTERY 

750. A number of battery faults may be deter¬ 
mined by observation of the conditions. These items 
are explained in the following sections. 

751. If, in testing the specific gravity or voltage 
of the cells, it is found that one cell is muck below 
the others or entirely dead, it may be due to any of 
the following reasons: 


BATTERY TROUBLE 


217 


Overfilling (704). 

Electrolyte replaced in wrong cell (705). 

Impure water added (707). 

Electrolyte or acid added to cells (708). 

Battery has been dropped (717). 

Low gravity long continued (721). 

Battery loose in carrier (730). 

Battery overheated (759, 760). 

Low charge or no charge, Chart N (771). 

High charge rate (772). 

Excessive overcharging (774). 

Overloads, Chart M (775). 

752. If one cell has continued for any length of 
time with low specific gravity, it may be subject to 
sulphatcd plates, buckled plates, frozen electrolyte or 
reversed negatives. 

753. The normal life of a battery is about 
eighteen months in regular service. If the- battery 
is older than this the insulators may be defective, 
there may be an excessive deposit of sediment or the 
grids themselves may be corroded. Reinsulated or 
rebuilt batteries will have added life. 

754. If an examination shows that the battery 
case has become rotted, the trouble may have resulted 
from any of the following reasons: 

Overfilling (704). 

Spilled electrolyte (713). 

Battery has been dropped (717). 

Battery loose in carrier (730). 

No air space around battery (732). 

Vent plugs loose or cracked (756). 

Defective sealing (758). 

Excessive overcharging (774). 

755. Should the battery case be found rotted, the 


218 


STARTING AND LIGHTING TROUBLES 


following conditions may also be present: Buckled 
plates, broken jars or frozen electrolyte. 

756. Except while being charged from a source 
outside the car, the vent plugs should always be se¬ 
curely screwed in place to prevent leakage of the 
electrolyte. Cracked or broken plugs should also be 
looked for. Some types of battery require that the 
vent plugs be in place even while charging off the car. 

757. The posts sticking up through the tops of 
the cells should be examined for looseness and if any 
is found it may indicate that the post or connectors 
inside the cell have been broken away from the plates. 
If the connecting bars between the posts are found 
to be loose, they should be clamped tightly or, if of 
the burned on type, should be properly burned in 
place. 

758. Defective sealing may be found, especially 
on a battery that has recently been repaired. This 
fault will allow leakage of the electrolyte and conse¬ 
quent damage to the terminals and battery case. 

759. If the connecting bars, posts or tops of the 
cells feel very warm to the hand at any time, the tem¬ 
perature of the electrolyte should be tested with a 
dairy thermometer. If the temperature is found 
above 100° or 105° Fahrenheit, it may result from 
any of the following causes: 

Electrolyte level low (701, 702). 

Impure water added to cells (707). 

Electrolyte or acid added to cells (708). 

Anti-freeze added to cells (709). 

Battery idle without, charge (720). 

Continued low gravity (721). 

Connections reversed (743). 

Uneven charge or discharge (744). 


BATTERY TROUBLE 


219 


Battery old (753). 

High charge rate, Chart 0 (772). 

Excessive overcharge (774). 

Battery capacity small (776). 

760. Overheating may result in sulphated plates, 
buckled plates, damaged insulators, excessive sedi¬ 
ment, or broken jars. 

CHARGE AND DISCHARGE 

770. The battery must be charged at a rate that 
is neither too high nor too low for its capacity and for 
the current that it is called upon to deliver. The dis¬ 
charge must not be at a rate too great for the battery 
capacity. The total discharge must be at least 20 per 
cent less in ampere-hours than the total charge in 
ampere-hours. 

771. If the charge is thought to be too low for the 
work being done by the battery the instructions in 
Chart N should be followed. 

772. If the charge rate is too high for the battery 
capacity, that is, if the charge in amperes is much 
above 1/8 of the battery capacity in ampere-hours, 
the instructions in Chart 0 should be followed. 

773. If the specific gravity of the liquid is found 
to be above 1.300, the instructions in Chart O should 
be followed. Excessively high specific gravity may 
result in sulphated plates, damaged separators or cor¬ 
roded grids. 

774. Even with a normal maximum charge rate, 
the battery may be overcharged because of receiving 
this rate for too great a length of time without cor¬ 
responding discharge. Such conditions obtain on 
long daylight runs, such as while touring; or with a 
car that is driven a great deal during the daytime 


220 STARTING AND LIGHTING TROUBLES 

with very little night driving. Under such conditions 
the charge rate may be cut down by the regulating 
system (400) or, while touring, the charge may be 
stopped by short circuiting the dynamo terminals. 
The charge may be cut down during daylight driving 
by turning on some or all of the lamps. Excessive 
overcharge may cause buckled plates, damaged in¬ 
sulators or broken jars. 

775. If a test of the discharge indicates any form 
of overload, or if the battery gravity or voltage indi¬ 
cates this condition, the instructions in Chart M should 
be followed. 

776. The capacity of the battery may be checked 
with the information given in Tables Y and YI pro¬ 
vided there is any doubt as to its being large enough 
for the work to be done. 

777. Overloads of any kind may finally result in 
either sulphated or buckled plates. 


BATTERY REPAIRS 

780. A storage battery should only be taken 
apart or repaired internally in a shop especially 
equipped for such work. If it is found that the bat¬ 
tery has been repaired outside of a well prepared bat¬ 
tery station any of the faults mentioned in the follow¬ 
ing sections may be present. 

781. If the lead burning or assembling and seal¬ 
ing of the cells has not been properly performed it 
may be that the plates are broken away from the con¬ 
necting straps, or that the posts are broken away 
from the connecters. 

782. Wood insulators must be kept moist at all 
times whether in the battery or out of it. If insulators 


BATTERY TROUBLE 


221 


are allowed to dry out and are then used in a battery, 
they will not give satisfactory service. 

783. Wood insulators must be placed between the 
plates so that the grooved sides of the insulators are 
next to the positive plates in all cases. 

784. If one or more insulators have been omitted 
from between the plates, this omission will cause a 
dead short circuit in the cell, resulting in its com¬ 
plete discharge and in the possibility of reversed 
negatives. 

785. The negative plates should be kept im¬ 
mersed in distilled water or in weak electrolyte at all 
times while removed from the battery. Otherwise the 
plates will become buckled and hardened. 

786. The positive plates should not be exposed 
to strong light while removed from the battery. Such 
exposure will cause these plates to buckle. 

787. No form of soldering flux should be used 
in lead burning. Its use will cause high resistance 
and corrosion at the parts thus joined. 

GRAVITY AND VOLTAGE TESTS 

788. Specific Gravity Test. —The condition of 
charge or discharge of a battery may be determined 
by testing the acid density of the liquid electrolyte by 
means of a hydrometer as shown in Figure 85. 

The hydrometer itself consists of a weighted bulb 
having a scale carried by an upward extension. This 
scale is marked from 1.100 to 1.300 in most instru¬ 
ments, the smaller number being near the top. The 
hydrometer is enclosed by a syringe having a rubber 
bulb at the upper end and a nozzle at the lower end. 

With the syringe bulb compressed, the nozzle is 
dipped into the electrolyte of the cell to be tested and 


•Z22 STARTING AND LIGHTING TROUBLES 

a portion of the liquid drawn up. The point of the 
hydrometer scale at which the liquid level comes, indi¬ 
cates the strength of the solution and is read as the 
specific gravity of that cell. 



Figure 85.—Battery Testing Hydrometer. 


789. Total Voltage of Battery. —A voltmeter 
having a range at least as high as the voltage of the 
battery is connected across the positive and negative 
terminals as shown in Figure 86 at the left. To be of 
any value the reading should be taken while the bat¬ 
tery is charging or discharging. The voltage of a 



















































BATTERY TROUBLE 


223 


battery at rest will be about the same regardless of 
its condition. 

790. Cell Voltage. —A voltmeter reading up to 
three volts is connected between the two terminals 
of the cell to be tested as shown in Figure 86 at the 
right. A completely discharged battery will show 
a discharge voltage of 1.7 to 1.8, while a charged bat¬ 
tery will show a charging voltage between 2.4 and 2.7. 














224 


STARTING AND LIGHTING TROUBLES 



Battery, storage 


o 


o 

H 

11 


Condenser 


Contact points 


Dynamo or generator 


Field coil 


Fields, series and shunt 




Ser/es 

S/iunf' 


Fuses 

Ground connection 



Figure 87.—Symbols Used in Wiring Diagrams. 






















BATTERY TROUBLE 


225 



Housing - or framej 

I 


I_ 



/ 

1 


\ 


N 


\ 

I 

/ 

/ 


Line to lamp, horn, ignition. 

etc. 

Line to dash or cowl lamps 

Line to head lamp large bulbs 

Line to side lamps or dim 

bulbs 


z 

D 

5 


Line to tail lamp 


T 


Magnet 


Motor-dynamo 


Motor, starting 



Negative 


Positive 



Figure 88.—Symbols Used in Wiring Diagrams 









STARTING AND LIGHTING TROUBLES 


26 


Resistance coil 


MAA/V 


Terminal 



Tester: ammeter, voltmeter or 

lamp 





Winding's, series and shunt 



Wires crossing without con¬ 
nection 


Wires joined 



Wire, starting circuit 
Wire, other circuits 


figure 89.—Symbols Used in Wiring Diagrams. 










CHAPTER XI 


TABLES, RULES AND DATA 
OHM ’s LAW 

Ohm’s law expresses the relation between the am¬ 
perage of a current, the pressure exerted and the 
resistance being overcome. The current is measured 
in amperes, the pressure in volts and the resistance 
in ohms. Knowing any two of these for a circuit, the 
third may be found as follows: 

Amperes are found by dividing the number of volts 
by the number of ohms. 

Volts are found by multiplying the number of am¬ 
peres by the number of ohms. 

Ohms are found by dividing the number of volts 
by the number of amperes. 

Ohm’s law may also be expressed in formulas as 
shown below. In these formulas, C stands for the 
current in amperes, E stands for the pressure in volts, 
and R stands for the resistance in ohms. 



R 


e = cxr 


R = CXE 


227 


228 


STARTING AND LIGHTING TROUBLES 


TABLE I 

RESISTANCE OF COPPER WIRE 



RESISTANCE 


RESISTANCE 

GAGE 

IN OHMS PER 

GAGE 

IN OHMS PER 

SIZE 

1000 FT. 

SIZE 

1000 FT. 

0000 

.049 

19 

8.038 

000 

.062 

20 

10.140 

00 

.078 

21 

12.78 

0 

.098 

22 

16.12 

1 

.124 

23 

20.32 

2 

.156 

24 

25.63 

3 

.197 

25 

32.31 

4 

.249 

26 

40.75 

5 

.313 

27 

51.38 

6 

.394 

28 

64.79 

7 

.497 

29 

81.70 

8 

.627 

30 

103.00 

9 

.791 

31 

129.90 

10 

.997 

32 

163.80 

11 

1.257 

33 

206.6 

12 

1.586 

34 

260.5 

13 

1.999 

35 

328.4 

14 

2.521 

36 

414.2 

15 

3.179 

37 

522.2 

16 

4.009 

38 

658.5 

17 

5.055 

39 

830.4 

18 

6.374 

40 

1047.0 


Note: Resistance increases 0.4 of 1% for each degree 
rise in temperature above 60° F. 


TABLES, RULES AND DATA 


221) 


TABLE II 

MINIMUM WIRE SIZE 

LIGHTING, CHARGING AND ACCESSORY FEED WIRES 

Calculated for 6 volt circuit with 4% drop in voltage. 
For intermediate values, use next larger size. Read wire 
gage at intersection of columns for amperage and length. 


MAXIMUM TOTAL LENGTH OF WIRE IN FEET 

FLOW IN 


AMPERES 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

12 

14 

16 

18 

20 

25 

1 

33 

30 

28 

27 

26 

26 

25 

24 

24 

23 

23 

22 

21 

21 

20 

19 

2 

30 

27 

26 

24 

23 

23 

22 

21 

20 

20 

20 

19 

18 

18 

17 

16 

3 

28 

26 

24 

23 

22 

21 

20 

20 

19 

19 

18 

17 

17 

16 

16 

15 

4 

27 

24 

23 

21 

20 

20 

19 

18 

18 

17 

17 

16 

15 

15 

14 

13 

5 

26 

23 

22 

20 

19 

19 

18 

18 

17 

16 

16 

15 

14 

14 

13 

12 

6 

26 

23 

21 

20 

19 

18 

17 

17 

16 

16 

15 

14 

14 

13 

13 

12 

7 

25 

22 

20 

19 

18 

17 

16 

16 

15 

15 

14 

13 

13 

12 

12 

11 

8 

24 

21 

20 

18 

17 

17 

16 

15 

15 

14 

14 

13 

12 

12 

11 

10 

9 

24 

20 

19 

18 

17 

16 

15 

15 

14 

14 

13 

12 

12 

11 

11 

10 

10 

23 

20 

19 

17 

16 

16 

15 

14 

14 

13 

13 

12 

11 

11 

10 

9 

11 

23 

20 

18 

17 

16 

15 

14 

14 

13 

13 

12 

11 

11 

10 

10 

9 

12 

23 

20 

18 

17 

16 

15 

14 

13 

13 

13 

12 

11 

11 

10 

10 

9 

13 

22 

19 

17 

16 

15 

14 

14 

13 

13 

12 

11 

11 

10 

10 

9 

8 

14 

22 

19 

17 

16 

15 

14 

13 

13 

12 

12 

11 

10 

10 

9 

9 

8 

15 

22 

19 

17 

16 

15 

14 

13 

13 

12 

12 

11 

10 

10 

9 

9 

8 

16 

21 

18 

17 

15 

14 

13 

13 

12 

12 

11 

10 

10 

9 

9 

8 

7 

17 

21 

18 

16 

15 

14 

13 

13 

12 

11 

11 

10 

10 

9 

9 

8 

7 

18 

21 

18 

16 

15 

14 

13 

12 

12 

11 

11 

10 

9 

9 

8 

8 

7 

19 

21 

18 

16 

14 

14 

13 

12 

12 

11 

11 

10 

9 

9 

8 

8 

7 

20 

20 

17 

16 

14 

13 

13 

12 

11 

11 

10 

10 

9 

8 

8 

7 

6 

21 

20 

17 

15 

14 

13 

12 

12 

11 

11 

10 

9 

9 

8 

8 

7 

6 

22 

20 

17 

15 

14 

13 

12 

11 

11 

10 

10 

9 

8 

8 

7 

7 

6 


230 


STARTING AND LIGHTING TROUBLES 


TABLE II. (Continued) 


MAXIMUM 




TOTAL 

LENGTH OF WIRE 

IN 

FEET 




FLOW IN 

AMPERES 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

12 

14 

16 

18 

20 25 

23 

20 

17 

15 

14 

13 

12 

11 

11 

10 

10 

9 

8 

8 

7 

7 

6 

24 

20 

16 

15 

13 

13 

12 

11 

10 

10 

10 

9 

8 

8 

7 

7 

6 

25 

19 

16 

15 

13 

12 

12 

11 

10 

10 

9 

9 

8 

7 

7 

6 

5 

.26 

19 

16 

14 

13 

12 

11 

11 

10 

10 

9 

8 

8 

7 

7 

6 

5 

27 

19 

16 

14 

13 

12 

11 

11 

10 

9 

9 

8 

8 

7 

6 

6 

5 

28 

19 

16 

14 

13 

12 

11 

10 

10 

9 

9 

8 

7 

7 

6 

6 

5 

29 

19 

16 

14 

13 

12 

11 

10 10 

9 

9 

8 

7 

7 

6 

6 

5 

30 

19 

16 

14 

13 

12 

11 

10 10 

9 

9 

8 

7 

7 

6 

6 

5 


Note: The gage sizes shown in heavy type toward the 
right should be used if possible because smaller sizes are 
subject to heating. 


TABLES, RULES AND DATA 


231 


TABLE III 

MINIMUM WIRE SIZE 


STARTING CABLES 


Calculated for a drop of % volt. For intermediate values, 
use next larger size. Read wire gage at intersection of 
columns for amperage and length. 


MAXIMUM 



TOTAL 

LENGTH OF 

WIRE 

IN 

FEET 



FLOW IN 

AMPERES 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

I 100 

4 

4 

4 

4 

4 

4 

4 

4 

4 

4 

150 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

200 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

250 

3 

3 

3 

3 

3 

3 

3 

3 

3 

3 

300 

3 

3 

3 

3 

3 

3 

3 

3 

2 

<y 

LJ 

350 * 

3 

3 

3 

3 

3 

3 

3 

2 

2 

1 

400 

3 

3 

3 

3 

3 

3 

2 

2 

1 

1 

450 

3 

3 

3 

3 

2 

2 

2 

1 

1 

0 

500 

3 

3 

2 

o 

u 

2 

2 

1 

1 

0 

0 

600 

2 

2 

2 

2 

2 

1 

0 

0 

00 

00 




TABLE 

IV 







CURRENT REQUIRED BY LAMPS 

The table gives the amperage required for each candle- 
power of the various types and sizes of lamps at six volts. 

For twelve volt lamps, the current is one-half the amount 
given. 


TYPE OF 

LAMPS CANDLEPOWER OF LAMPS 

1 to 6 8 to 12 15 to 21 24 to 40 

TUNGSTEN.21 .19 .17 .15 

NITROGEN . .13 .12 

CARBON.50 .45 .40 


To find the amperage that should flow through any 
lighting line, first count the total candlepower of the 
lamps fed by that line, then multiply this candlepower 
by the decimal fraction given above for the kind and 
size of lamps being used. The result is the total am¬ 


perage. 





2S2 


STARTING AND LIGHTING TROUBLES 


TABLE V 

REQUIRED BATTERY CAPACITY IN AMPERE-HOURS 

TO CARRY LAMP LOAD 

Requirements based on lighting service with dynamo idle 
for given number of hours. The table takes into account 
the change in battery efficiency caused by the rate of cur¬ 
rent withdrawal. Read ampere-hour capacity at intersec¬ 
tion of columns for amperes and hours. 


TOTAL LAMP NUMBER OF HOURS LAMPS CAN BE BURNED 


LOAD IN 


AMPERES 

4 

6 

8 

2 

20 

20 

25 

3 

20 

25 

30 

4 

25 

35 

45 

5 

30 

45 

55 

6 

35 

50 

65 

7 

40 

55 

70 

8 

45 

65 

80 

9 

55 

75 

90 

10 

60 

85 

105 

11 

65 

90 

110 

12 

70 

100 

120 

13 

75 

105 

130 

14 

85 

110 

135 

15 

90 

115 

140 


CONTINUOUSLY 


10 

12 

14 

16 

18 

20 

25 

25 

30 

35 

40 

45 

40 

45 

50 

55 

60 

65 

50 

60 

70 

75 

80 

90 

60 

75 

85 

90 

105 

110 

75 

85 

100 

105 

120 

130 

85 

100 

115 

120 

140 

160 

100 

115 

135 

140 

160 

180 

115 

130 

150 

160 

180 


130 

150 

165 

180 



140 

165 

180 





150 175 
155 180 
160 
165 


TABLE VI 


REQUIRED BATTERY CAPACITY IN AMPERE-HOURS 
FOR STARTING ENGINES 


Requirements based on starting engine when cold and 
with a gear reduction of 10 to 1 between armature shaft 
and engine flywheel or crank shaft. Battery capacity will 
be found at intersection of lines for bore and stroke in sec¬ 
tion of table covering given number of cylinders. 

This table should be used in connection with Table Y 
which gives battery capacity for carrying lamp loads. Which¬ 
ever function, lighting or starting, requires the larger bat¬ 
tery; that larger size should be installed on the car. 


FOUR CYLINDER ENGINES 


Xt 


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STARTING AND RIGHTING TROUBLES 





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TABLES, RULES AND DATA 


235 


TABLE VII 

STARTING AND RUNNING TORQUE IN FOOT POUNDS 
REQUIRED FOR AUTOMOBILE ENGINES 

Torque is found at intersection of lines for bore and 
stroke. The table is based on four cylinder engines. Six 
cylinder engines require 1 y 2 times the torque given, eight 
cylinder engines require twice as much and twelve cylinder 
types require three times the torque. 

Heavy faced figures give torque required for starting the 
engine from rest. 

Light faced figures give torque required to keep the en¬ 
gine turning. 


BORE STROKE IN INCHES 

IN 


INCHES 

334 

^3 

CO 

4 

41/4 

4y 2 

4% 

5 

5 Vi 

5 % 

5% 

6 

3 

50 

53 

56 

59 

62 

65 

68 

71 

74 

77 

80 


11 

11 

12 

13 

14 

14 

15 

16 

17 

17 

18 

334 

58 

61 

64 

67 

70 

74 

77 

81 

84 

87 

90 

12 

13 

14 

15 

16 

17 

18 

18 

19 

20 

21 

334 

65 

69 

73 

77 

80 

84 

87 

90 

94 

97 

100 


15 

16 

17 

18 

19 

20 

21 

22 

23 

24 

25 

m 

72 

77 

83 

87 

91 

94 

97 

100 

104 

107 

110 

17 

18 

19 

20 

21 

22 

23 

25 

26 

27 

28 

4 

81 

86 

91 

96 

100 

105 

109 

113 

116 

119 

122 


19 

20 

21 

23 

24 

26 

27 

28 

30 

31 

33 

434 

90 

94 

98 

103 

108 

112 

116 

119 

122 

125 

128 

21 

23 

24 

25 

27 

28 

30 

31 

33 

34 

35 

434 

97 

102 

107 

112 

116 

121 

126 

131 

135 

140 

145 

24 

25 

27 

29 

30 

32 

34 

36 

37 

39 

41 

43/4 

105 

111 

116 

121 

126 

131 

136 

142 

147 

152 

157 

26 

28 

30 

32 

34 

36 

38 

40 

42 

44 

45 

5 

112 

119 

126 

132 

137 

142 

147 

153 

158 

164 

170 


29 

31 

33 

36 

38 

40 

42 

44 

46 

48 

50 


Formula for prony brake scale reading 

^ 12 x (torque given in table) 

Required Reading ( g ear reduction) x (radius of pulley) 




235a 


STARTING AND LIGHTING TROUBLES 


TEST BENCH WIRING 

In Figure 89 is shown a wiring plan for a test 
bench designed to handle dynamo work, general cir¬ 
cuit testing and ignition work. Figure 90 shows 
the same bench with the addition of a high reading 
ammeter and the necessary leads for making tests 
on starting motors. Figure 91 shows the layout of 
the parts required for the complete bench. 

Referring to Figure 89, two six-volt batteries are 
connected as shown to a three-pole, double-throw 
knife switch. Throwing this switch toward the right 
sends six volt current through the circuits and con¬ 
nects the two batteries in parallel with each other. 
Throwing this switch to the left connects the two 
batteries in series with each other and sends a twelve 
volt current through the circuits. A double-throw, 
two-pole switch is connected to the vise which holds 
the dynamo, starter or ignition unit being tested. 
Throwing this switch to the right grounds the nega¬ 
tive side of the batteries and all circuits to the vise. 
Throwing this switch to the left grounds the posi¬ 
tive side of the batteries and all circuits. 

The voltmeter, in the upper left hand corner of the 
bench panel, is connected to a single-pole, double¬ 
throw voltmeter switch and to the two terminals 
marked “volts. ” With this switch at the right, the 
voltmeter is connected to the panel so that it indi¬ 
cates the voltage of dynamos or starting motors being 
tested in the vise. Throwing this switch to the left 
disconnects the meter from the panel and connects it 
to the two terminals so that with leads on these ter¬ 
minals any desired voltage tests may be made inde¬ 
pendently of the bench itself. 

Below the voltmeter are two cut-outs, one twelve 


TABLES, RULES AND DATA 


235b 


volt and the other six volt, so connected that they 
are controlled by the three-pole voltage change switch 
already described. Near the center of the panel are 
two lamp sockets, one to be a single contact type and 
the other a double contact for testing lamp bulbs. 

The ammeter, near the upper right hand corner of 
the bench panel, is connected to a double-pole, double- 
throw switch marked “ammeter switch.” "With this 
switch thrown to the left the ammeter is connected 
to the panel so that it measures the current from a 
dynamo being tested in the vise, that is, the charge 
current. With this switch thrown to the right the 
ammeter is disconnected from the panel and connected 
to the two terminals marked “amperes” so that leads 
from these terminals may be used in making any 
desired current readings such as measuring field cur¬ 
rent, motoring current, etc. At the same time the 
charging circuit on the panel is completed between 
dynamo and batteries without the ammeter in circuit. 

Referring to the seven terminals below the am¬ 
meter position in Figure 89, the upper left hand, 
marked “generator” is connected to the battery or 
cut-out terminal on a dynamo being tested in the 
vise. The ground switch is turned to the position 
that suits the dynamo under test according to whether 
the system grounds the negative or the positive. 

The two terminals marked “battery” are used as 
a source of supply for battery current in making 
ignition tests, motoring tests, etc. Either six or twelve 
volt pressure may be had at these terminals by chang¬ 
ing the voltage switch to the six or twelve volt side. 

The two terminals marked “test” are connected 
with the main supply line, 110-volt or 220-volt as the 
case may be, and in series with them is the test lamp 


\ 


235c STARTING AND LIGHTING TROUBLES 

shown just below the ammeter. Leads from these 
two terminals are used for making circuit tests in 
which a high voltage current is desired, such as on 
condensers, etc. 

Figure 90 shows the same wiring as on Figure 89, 
but one more terminal is added to the bank of ter¬ 
minals below the small ammeter and a high reading 
ammeter with its external shunt is added in the 
upper center of the panel. This added terminal is 
Connected to the main battery or starting switch ter¬ 
minal on a starting motor being tested in the vise. 
The bench grounding switch is used as a starting 
switch, being kept open until it is desired to send 
current to the motor, after which it is closed on either 
side according to the polarity grounded. 

The small meter at the extreme left in Figure 90 
is an alternating current voltmeter for making mag¬ 
neto tests. Of the four small terminals at the ex¬ 
treme right side of the bench, the left hand pair are 
for a growler and the right hand pair for a remag- 
netizer. 


i 


TABLES, RULES AND DATA 


235<i 


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235e 


STARTING AND LIGHTING TROUBLES 



■Wiring - Plan fnr a Test Bench Handling All Tests, Including Those for 

Starting Motors. 





































































































Figure 91.—Layout of Parts on a Complete Test Bench with Battery Discharge Set. 


TABLES. RULES AND DATA 


235f 



















































































































236 


STARTING AND LIGHTING TROUBLES 


TABLE VIII 

OUTPUT RATES AND REGULATION 

The maximum output in amperes of dynamos of 
various makes and types is given in the following 
table. This current should be measured with an am¬ 
meter in series at the dynamo, with all lamps turned 
off and with the battery charged to a specific gravity 
of 1.250 or more. Any exceptions to this rule are 
mentioned. 

This table gives information only for those systems 
not shown in the section of wiring diagrams. Com¬ 
plete specifications of all other equipments are shown 
opposite the corresponding diagram. 

The information given on pages opposite the in¬ 
ternal wiring diagrams for the various systems and 
models of equipment is arranged according to the 
following form : 

NAME OF MAKER Type and Model 

Units Mentions the various parts of the 

equipment as found on the car and 
tells what electrical units are con¬ 
tained in each part. 

Voltage The voltage used for charging, starting 

and lighting. 

Output The normal or maximum output of the 

dynamo in amperes as found under 
certain conditions. 

Regulation The method or system used to control 

the amperage or voltage of the dy¬ 
namo, also reference to the sections 
of the book in which the method is 
fully described. 


TABLES, RULES AND DATA 


237 


Cut-out 

Fuses 

Remarks 


Mentions the type of cut-out and gives 
brief description. 

Mentions those used and tells where 
they are found. 

Any special information that is use¬ 
ful in making tests and repairs. 


NAME AND TYPE REGULATION VOLT- MAX. SECTIONS ON 

METHOD AGE AMPER. ADJUSTMENT 


238 STARTING AND RIGHTING TROUBLES 


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TABLES, RULES AND DATA 



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240 


STARTING AND LIGHTING TROUBLES 


ADLAKE 

Units 


Voltage 

Output 

Regulation 

Cut-out 


Fuses 

Remarks 


Dynamo: Shunt wound, two field coils, 
two brushes. 

Dash Unit: Contains current regu¬ 
lator at top, cut-out in lower right 
corner, head lamp switch above cut¬ 
out, main line fuse and field fuse in 
lower left corner. 

6 

15 to 20 amperes maximum. 

Amperage control by solenoid con¬ 
trolled rheostat. See section 467. 

Electromagnetic with two sets of mag¬ 
nets, shunt above and series below. 
Contact gap adjustable by screw. 

Main line (upper) 10 or 15 ampere. 
Field (lower) 5 ampere. 

A small switch in the upper left hand 
corner of the dash unit will allow a 
continuous high output regardless of 
the position of the head) lamp switch. 
XI 


Drawing 


INTERNAL WIRING DIAGRAMS 


241 






































































242 


STARTING AND RIGHTING TROUBLES 


ALLIS CHALMERS Motor-Dynamo. 

Units Motor-Dynamo: Shunt and series 

wound, four field coils, four brushes. 

Controller: Combined cut-out and cur¬ 
rent regulator with main line fuse 
on cover. 

Starting Switch: Contains auxiliary 
contacts which open charging cir¬ 
cuit when starting contacts are 
closed. 

Voltage 6 

Output 10 amperes. 

Regulation Constant amperage with vibrating reg¬ 

ulator and field resistance. See Sec¬ 
tions 421 and 429 to 431. 

Cut-out Electromagnetic combined with regu¬ 

lator. 

Fuses Main line fuse on controller cover, 45 

ampere. 

AC1 


Drawing 


INTERNAL WIRING DIAGRAMS 


243 



A /e/d Res/sfdnce 
























































244 


STARTING AND LIGHTING TROUBLES 


APLCO 

Units 


Voltage 

Output 


Regulation 


Cut-out 

Fuses 

Remarks 


Motor-Dynamo, 6-30 Volt System. 

Motor-Dynamo: Shunt and series 

wound, four field coils, four brushes. 

Dash Unit: Contains commutating 
switch for changing voltage during 
starting and running, drum lighting 
switch, cut-out, stop charge relay, 
starting and lighting fuses, pilot 
lamp and switches for pilot and dash 
lamp. 

6 for charging. 30 for starting. 

22 amperes maximum with discharged 
battery and at high speed. With 
battery charged, the output falls 
nearly to zero. 

Output limited by motor-dynamo field 
windings while stop charge relay con¬ 
tacts are closed. When battery volt¬ 
age reaches 2 y 2 per cell, relay con¬ 
tacts open and reduce the charge 
until battery voltage falls. See sec¬ 
tion 470. Screw adjustment for gap. 

Electromagnetic, carried in dash unit. 
Screw adjustment for gap. 

Two, carried in dash unit. Upper fuse 
for starting, 50 ampere. Lower fuse 
for lighting, 25 ampere. 

The pilot lamp on the dash unit burns 
brightly with the cut-out closed and 
burns dimly with cut-out open. This 
lamp is turned on and off by the left 
hand switch on top of the dash unit. 
T1 


Drawing 



INTERNAL. WIRING DIAGRAMS 


245 














































































































































246 


STARTING AND LIGHTING TROUBLES 


APLCO 

Units 


Voltage 

Output 

Regulation 


Cut-out 


Fuses 


Drawing 


Separate Dynamo, Carbon Disc Reg¬ 
ulation. 

Dynamo : Shunt wound, four field coils, 
two brushes. 

Dash Unit: Contains current regulator, 
cut-out, lighting fuse and field fuse. 

6 

10 amperes. 

Amperage controlled by carbon disc 
field resistance which is varied by 
magnetism of solenoid coil in charg¬ 
ing circuit. See section 469. 

Electromagnetic in right hand side of 
dash unit. Adjusted by screw which 
is exposed with the right hand screw 
cap removed. 

Two, on dash unit. Field fuse, left 
hand, 3 ampere. Lighting fuse, right 
hand, 25 ampere. 

T2 


INTERNAL WIRING DIAGRAMS 


247 



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248 


STARTING AND LIGHTING TROUBLES 


APLCO 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Fuses 


Separate Dynamo, Third Brush System, 

Dynamo: Shunt wound, four field coils, 
two main brushes and one regulating- 
brush. 

Cut-out: Also carries lighting fuse. 
This is the same type of cut-out as 
used with Splitdorf-Apelco systems. 

6 

8 amperes maximum. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Electromagnetic in separate unit. 

Lighting fuse may be carried on cut¬ 
out. 10 or 15 ampere capacity. 

T3 


Drawing 


249 


INTERNAL WIRING DIAGRAMS 



I 


A 






















































250 


STARTING AND LIGHTING TROUBLES 


AUTOUTE 

Units 

Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Constant Speed, Permanent Magnet 
Dynamo. 

Dynamo : Permanent magnet fields, two 
brushes. Cut-out carried under arch 
of magnets. 

6 

17 amperes maximum with discharged 
battery. 

Constant voltage maintained by con¬ 
stant speed with slipping clutch gov¬ 
ernor. See sections 440, 442 and 444. 

Electromagnetic carried, under dynamo 
field magnet arch. 

A1 


INTERNAL WIRING DIAGRAMS 




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STARTING AND LIGHTING TROUBLES 


2;>2 

AUTOLITE 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


i 

i 


Arched Field Frame Dynamo, Model 
“G.” 

Dynamo: Shunt and reversed series 
windings, single field coil, two 
brushes. 

Cut-out: Separate unit. 

Starting Motor: Series wound, four 
field coils, four brushes. 

Starting Switch: Single pole. 

6 

15 amperes maximum. 

Reversed series field winding. See sec¬ 
tion 461. 

Electromagnetic in separate housing. 

A2 






INTERNAL. WIRING DIAGRAMS 


253 









































































254 


STARTING AND LIGHTING TROUBLES 


AUTOLITE 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Enclosed Dynamo, Reversed Series, 
Type “GO.” 

Dynamo: Shunt and reversed, series 
fields, two field coils, two brushes. 

Cut-out: Electromagnetic, separate 

unit. 

Starting Motor: Series wound, four 
field coils, four brushes. 

Starting Switch: Single pole. Mov¬ 
able contact carried on gear shifter 
rod. Rod cannot be moved until 
solenoid operated latch is released by 
pressing button on steering column 
switch. 

6 

14 amperes maximum. 

Reversed series field winding. See sec¬ 
tion 461. 

Electromagnetic in separate housing. 

A3. External circuits in this drawing 
also apply to dynamos shown in 
drawing A4. 



INTERNAL. WIRING DIAGRAMS 


255 














































































256 


STARTING AND LIGHTING TROUBLES 


AUTOLITE 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Third Brush Dynamo. 

Dynamo: Shunt wound, two field coils, 
two main brushes and one regulat¬ 
ing brush. 

Cut-out: Separate unit. 

Starting Motor: Series wound, four 
field coils, four brushes. 

Starting Switch: Single pole. 

6 

15 amperes maximum. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Electromagnetic in separate housing. 

A4, right hand side. External circuits 
are the same as shown in drawing A3. 






INTERNAL WIRING DIAGRAMS 257 





























































STARTING AND LIGHTING TROUBLES 


2T>8 


BIJUR 

Units 


Voltage 

Output 


Regulation 


Cut-out 


Remarks 


Drawing 


Constant Voltage System. 

Dynamo: Shunt wound, four field coils, 
two brushes. 

Controller: Carried on top of dynamo. 
Contains cut-out and regulator. 

6 

Depends on battery charge. High rate 
to discharged battery and low rate 
to charged battery. Ranges from 5 
to 16 amperes. Dynamo voltage 
maintained constant regardless of 
speed. 

Constant voltage maintained by vibra¬ 
tor with resistance in shunt field cir¬ 
cuit. Vibrator magnet acted upon by 
voltage between dynamo brushes. 
See sections 422 and 429 to 431. 

Electromagnetic, carried in controller 
case. Consists of a magnet separate 
from the regulator and carrying its 
own shunt and series windings. 

Leads to battery and outside lines start 
from a reversing plug in one end of 
the controller. This plug should be 
given a half turn once for each 500 
miles running. This reverses the 
dynamo polarity and causes an even 
action on the cut-out and regulator 
contacts. 

B1 


259 


N 


INTERNAL WIRING DIAGRAMS 







































260 


STARTING AND LIGHTING TROUBLES 


BIJUR 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Third Brush Dynamos. 

Dynamo: Shunt wound, four field coils, 
two main brushes and one regulating 
brush. Cut-out carried in dynamo 
housing. Field fuse in dynamo. 

6 

12 to 15 amperes maximum. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Electromagnetic in dynamo housing. 

B2. Upper drawing shows two term¬ 
inal dynamo for two wire system. 
Lower -drawing shows single terminal 
dynamo for grounded system, one 
wire. 


9k 




INTERNAL WIRING DIAGRAMS 




261 



























262 STARTING AND LIGHTING TROUBLES 

BIJUR Motor-Dynamo. 

Units Motor-dynamo: Shunt and series 

wound, four field coils, four main 
brushes and regulating brush. 

Switch: Single switch for starting and 
lighting. 

Voltag*© 12 

Output 6 to 7 amperes maximum. 

Regulation Third brush for field current. See sec 

tions 413 to 419. 

Cut-out Manual in switch. When the starting 

contacts are closed, the motor-dyna¬ 
mo is connected to the battery for 
starting. It is directly driven and 
as soon as its speed is sufficient, 
charging commences. With drop in 
speed the motor-dynamo again acts 
as a motor. Later switches have an 
idle position in which the shunt field 
circuit may be opened and the charge 
stopped with the engine still run¬ 
ning. 

B3 


Drawing 






















































STARTING AND LIGHTING TROUBLES 


BOSCH 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Constant Voltage System, “DeLuxe.” 

Dynamo: Shunt wound, two field coils, 
two brushes. 

Dash unit: Contains cut-out, voltage 
regulator, lighting switch and volt- 
ammeter with meter switch for read¬ 
ing volts or amperes. 

Starting Motor: Same as Rushmore 
on drawing 02. 

Starting Switch: Same as Rushmore 
on drawing 02. 

12 

* 

Depends on battery charge. High rate 
to discharged battery and low rate to 
charged battery. Ranges from 8 to 
10 amperes under ordinary condi¬ 
tions. 

Carbon and mica resistance in field cir¬ 
cuit. See section 466. 

Electromagnetic in left side of dash 
unit. 

Cl 


Bottom of cfjsh uny'f 


INTERNAL WIRING DIAGRAMS 


265 















































































2m 


STARTING AND LIGHTING TROUBLES 


BOSCH 

Units 


Voltage 

Output 

Regulation 


Cut-out 

Fuses 


Drawing 


Standard Systems. 

Dynamos: Two field coils, two brushes. 
Reversed series winding on DSG 5, 
6, 7, 8, 107 and 108. Compound wind¬ 
ing on DSG 105 and 106. 

Dash Unit: Contains cut-out, field fuse 
and lighting fuse. 

Switch Unit: Contains lighting switch, 
ignition switch and ammeter. 

Starting System: Same as Rushmore 
shown on drawing 02. 

6 or 12 

12 to 15 amperes on 6 volt system. 

6 to 8 amperes on 12 volt system. 

Reversed series field winding on dyna¬ 
mos DSG 5, 6, 7, 8,107 and 108. Com¬ 
pound field winding on dynamos DSG 
105 and 106. See section 461 for 
reversed series characteristics. The 
compound wound dynamos increase 
their output with increase in speed 
and in almost direct ratio. 

Electromagnetic in separate unit. 

Two, carried in cut-out housing. Light¬ 
ing fuse at left, 30 ampere. Field 
fuse at right, 3 ampere. 

C2. Upper dynamo DSG 105 and 106, 
compound wound. Lower dynamo 
DSG 5, 6, 7, 8, 107 and 108, reversed 
series wound. 


INTERNAL WIRING DIAGRAMS 


267 





























































































268 


STARTING AND LIGHTING TROUBLES 


BOSCH 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Magneto-Dynamo. 

Magneto-Dynamo: Shunt and reversed 
series winding, single field coil, two 
brushes. Cut-out in magneto-dynamo 
housing. The generating unit is car¬ 
ried above a high tension magneto 
similar to the Bosch Type “NU.” 

Switch Unit: Contains lighting switch, 
ignition switch and ammeter. 

6 or 12 

10 to 15 amperes on 6 volt system. 

5 to 8 amperes on 12 volt system. 

Reversed series field winding. See sec¬ 
tion 461. 

Electromagnetic, carried in magneto 
dynamo housing. 

C3 ' 






INTERNAL. WIRING DIAGRAMS 



Cut Out 




































270 


STARTING AND RIGHTING TROUBLES 


DEACO 

Units 


Voltage 

Output 


Regulation 

Cut-out 

Drawing 


Third Brush Dynamo. 

Dynamo : Shunt wound, four field coils, 
two main brushes and one regulating 
brush. 

Cut-out: Separate unit. 

Starting Motor: Series wound, four 
field coils, four brushes. 

Starting Switch: Single pole, double 
contact. Resistance in series on first 
contact point. 

6 

16 amperes maximum with 1:1 drive 
ratio. 

12 amperes maximum with l 1 /^ :1 drive 
ratio. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

E 1 ectromagnetic in separate unit. 

Y1 



INTERNAL WIRING DIAGRAMS 


271 




















































272 


STARTING AND LIGHTING TROUBLES 


DELCO 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Motor-Dynamo, 6-24 Volt System. 

Motor-Dynamo: Shunt and series field 
winding, two field coils, two brushes. 

Battery Box Unit: Contains four part, 
twelve cell battery; commutating- 
knife blade switch for starting and 
running; cut-out; ampere-hour meter 
and field resistances. 

Starting Latch: Engages starting 
switch and gear shifting mechanism 
with main clutch pedal when starting- 
button is pressed. 

6 for charging and lighting, 24 for 
starting. 

22 amperes maximum. 

Reversed series field windings while 
generating. Field resistance link on 
starting switch. Ampere-hour meter 
lowers or stops charge. See section 
464. 

Electromagnetic carried above starting 
switch. 

„ D1 



5/jrf/na sw/fch 


INTERNAL. WIRING DIAGRAMS 


273 


i 






































































































































STARTING AND LIGHTING TROUBLES 


274 


DELCO 

Units 


Voltage 

Output 


Regulation 

Cut-out 

Remarks 


Motor-Dynamo. Constant Voltage, Mer¬ 
cury Well Regulator. 

Motor-Dynamo : Shunt and series wind¬ 
ings, single field coil, two commuta¬ 
tors with two brushes for each. 
Armature has one commutator at 
each end and double winding on core. 
Starting commutator at rear, charg¬ 
ing at front. 

Starting Switch : At rear end of motor- 
dynamo. Sliding contact type. 

Apparatus Box: Contains voltage 
regulator, cut-out and ignition relay. 

Circuit Breaker : Used in place of fuses. 

Combination Switch: Lighting, igni¬ 
tion and starting button switches. 

6 

Depends on battery charge. High rate 
to discharged battery, low rate to 
charged battery. Ranges between 8 
and 12 amperes under ordinary con¬ 
ditions. 

Field resistance with mercury well. See 
section 468. 

Electromagnetic, carried in apparatus 
box. 

This system is being altered to do away 
with the mercury well regulator and 
to allow the motor-dynamo to act as 
a reversed series machine while gen¬ 
erating. 

D2 


Drawing 



INTERNAL, WIRING DIAGRAMS 


275 


t * £ * o * A 




















































































































276 


STARTING AND LIGHTING TROUBLES 


DELCO 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Motor-Dynamo. Junior System, 1914 
type. 

Motor-Dynamo : Three windings; shunt, 
reversed series and starting series 
in single coil. Two commutators, 
each with two brushes. Starting 
commutator at rear, dynamo commu¬ 
tator at front end. Armature carries 
two windings. Upper starting brush 
normally held away from commu¬ 
tator, acts as starting switch by drop¬ 
ping into contact for cranking opera¬ 
tion. Cut-out in upper part of motor- 
dynamo housing. 

6 

14 to 18 amperes maximum. 

Reversed series field winding. See sec¬ 
tion 461. 

Electromagnetic, in dynamo housing. 

D3 



✓ 


INTERNAL WIRING DIAGRAMS 277 















































































278 


STARTING AND LIGHTING TROUBLES 


DELOO 

Units 


Voltage 

Output 

Regulation 

Cut-out 


Drawing 


Motor-Dynamo. Junior System, 1915 
type. 

Motor-Dynamo : Three windings, shunt, 
reversed series and starting series in 
single field coil. Two commutators, 
each with two brushes. Starting 
commutator at rear, dynamo commu¬ 
tator at front. Armature carries two 
windings. Upper starting brush nor¬ 
mally held away from commutator; 
acts as starting switch by dropping 
into contact for cranking operation. 

Switch: Contains ignition, lighting and 
cut-out contacts, also circuit breaker. 

6 

14 to 18 amperes maximum. 

Reversed series field winding. See sec¬ 
tion 461. 

Manual. Each of the ignition switch 
plungers, “M” and “B,” carries an 
additional contact which closes the 
charging circuit when the ignition 
switch is closed. The resulting initial 
discharge through the motor-dynamo 
causes the armature to revolve slowly 
as the cranking gears are engaged. 

D4 




INTERNAL WIRING DIAGRAMS 


279 



* 

































































280 


STARTING AND LIGHTING TROUBLES 


DELCO 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Motor-Dynamo. Centrifugal Regula¬ 
tor, 1915 Standard System. 

Motor-Dynamo : Two windings, shunt 
for charging, series for starting in 
single field coil. Armature carries 
two windings, has starting commu¬ 
tator at rear end and dynamo com¬ 
mutator at front end, each commu¬ 
tator with two brushes. One starting 
brush normally held away from com¬ 
mutator; acts as starting switch by 
dropping into contact for the crank¬ 
ing operation. A pair of contacts 
interconnected with the starting 
brush switch opens the charging cir¬ 
cuit during cranking. 

Switch : Contains ignition, lighting and 
cut-out contacts, also the circuit 
breaker. 

6 

16 to 20 amperes maximum. 

Rheostat operated by centrifugal 
weight, controlling resistance in 
shunt field. See sections 445 to 450. 

Manual. Each ignition switch plunger 
carries additional contacts which 
close the charging circuit when the 
ignition switch is closed. The initial 
discharge through the motor-dynamo 
causes the armature to revolve slowly 
while the gears are engaged for 
cranking. 

D5 


INTERNAL WIRING DIAGRAMS 


281 

















































































282 


STARTING AND LIGHTING TROUBLES 


DELCO 

Units 


Voltage 

Output 

Regulation 


Cut-out 


Drawing 


Motor-Dynamo. Vibrating Regulator. 

Motor-Dynamo: Three field windings, 
shunt, reversed series and starting 
series in single field coil. Armature 
carries two windings, has starting 
commutator at rear and dynamo 
commutator at front, each commu¬ 
tator with two brushes. One starting 
brush normally held away from com¬ 
mutator and acts as starting switch 
by dropping into contact for the 
cranking operation. Contacts inter¬ 
connected with the starting brush 
switch open the charging circuit dur¬ 
ing cranking. 

Switch : Contains ignition, lighting and 
cut-out contacts, also the circuit 
breaker. 

6 ■ ■ 

15 amperes. 

Constant current controlled by vibrat¬ 
ing relay regulator. See sections 421 
and 429 to 431. 

Manual. Each ignition switch plunger- 
carries additional contacts which 
close the charging circuit -when the 
ignition switch is closed. The initial 
discharge through the motor-dynamo 
causes the armature to revolve slowly 
while the gears are engaged. 

D6. The switch and other external con¬ 
nections are the same as those shown 
in drawing D5. 


i/sruq DuijJP/S 
















































STARTING AND LIGHTING TROUBLES 


281 


DELCO 

Units 


Voltage 

Output 

Regulation 

Cut-out 


Drawing 


Motor-Dynamo. Third Brush System. 

Motor-Dynamo: Two field windings, 
shunt for generating, series for start¬ 
ing in single field coil. Armature 
carries two win-dings, has starting 
commutator at rear and dynamo 
commutator at front end. Each com¬ 
mutator has two brushes. One start¬ 
ing brush is normally held away from 
the commutator and acts as a start¬ 
ing switch by dropping into contact 
for the cranking operation. Contacts 
interconnected with the starting 
brush switch open the charging cir¬ 
cuit during cranking. 

Switch: Contains ignition, lighting 
and cut-out contacts, also the circuit 
breaker. 

6 

17 to 20 amperes maximum. 

Third brush for shunt field. See Sec¬ 
tions 413 to 419. 

Manual. The ignition switch plunger 
carries an additional contact which 
closes the charging circuit when the 
ignition switch is closed. The initial 
discharge through the motor-dynamo 
causes the armature to revolve slowly 
while the gears engage for cranking. 
D7 


INTERNAL WIRING DIAGRAMS 


285 
























































286 


STARTING AND LIGHTING TROUBLES 


DELCO 

Upper 


Lower 


Drawing 


Special Switches for Motor-Dynamos. 

Shows general type of rotary switch 
used by some cars in connection with 
motor-dynamos. 

Shows type of plunger switch having 
three sets of contacts on the ignition 
plungers. One set is for the ignition 
current, another set opens and closes 
the shunt field circuit, while the third 
set opens and closes the main charg¬ 
ing circuit. 

D8 


INTERNAL. WIRING DIAGRAMS 


287 




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288 


STARTING AND LIGHTING TROUBLES 


DELCO 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Separate Units. Third Brush System 

Dynamo : Shunt wound, two field coils, 
two main brushes and one regulating 
brush. Two outside leads, one to 
switch, one to ignition coil terminal. 

Motor: Series wound, four field coils, 
four brushes. 

Dash Switch: Contains ignition, light¬ 
ing and cut-out contacts, circuit 
breaker and ammeter. 

Starting Switch: Single pole. 

6 

16 to 20 amperes maximum. 

Third brush for field, current. See sec¬ 
tions 413 to 419. 

Manual, same as explained for drawing 

D7. 

D9 


INTERNAL WIRING DIAGRAMS 


289 












































200 


STARTING AND LIGHTING TROUBLES 


DELCO 

Units 


Voltage 

Output 

Regulation 

Cut-out 


Drawing 


Separate Units. Third Brush System. 

Dynamo : Shunt wound, two field coils, 
two main brushes and one regulating 
brush. One outside lead to dash 
switch. 

Motor: Series wound, four field coils, 
four brushes. 

Dash Switch: Contains ignition switch, 
lighting switch and circuit breaker. 

Starting Switch: Single pole. 

6 

16 to 20 amperes. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Manual. Ignition switch rotor carries 
additional contact which completes 
the charging circuit when the igni¬ 
tion switch is closed. 

DIO 


INTERNAL. WIRING DIAGRAMS 


291 








































STARTING AND LIGHTING TROUBLES 


• >r»2 


DELCO 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Remarks 


Separate Units. Third Brush. Double 
Rotary Switch. 

Dynamo: Shunt wound, two field coils, 
two main brushes and one regulating 
brush. One or two outside leads; 
second lead, when used, goes to ter¬ 
minal number 5 on switch. 

Motor: Series wound, four field coils, 
four brushes. 

Combination Switch: Contains rotor 
for lighting circuits, rotor for igni¬ 
tion and for manual cut-out contacts, 
also circuit breaker. 

6 ' 

16 amperes maximum. 

Third brush for shunt field current. 
See sections 413 to 419. 

Manual by means of contacts on igni¬ 
tion switch rotor from terminal 6. 

Either of the three dynamos shown at 
the right may be used; the center 
one having one main lead and an 
additional field lead to number 5 on 
the switch. Either of the three 
starting motors shown at the left 
may be used. 

Dll 


Drawing 


INTERNAL WIRING DIAGRAMS 


293 



























































294 


STARTING AND LIGHTING TROUBLES 


DELCO 


Units 


Voltage 

Output 

Regulation 

Cut-out 

Remarks 


Separate Units. Third Brush. Double 
Rotary Switch. Magnetic Cut-out on 
Dynamo. 

Dynamo: Shunt wound, two or four 
field coils, two main brushes and one 
regulating brush. Cut-out on dynamo 
housing. 

Motor: Series wound, four field coils, 
four brushes. 

Combination Switch: Contains rotor 
for lighting circuits, rotor for igni¬ 
tion, also circuit breaker. 

6 

16 amperes maximum. 

Third brush for shunt field current. 
See sections 413 to 419. 

Electromagnetic carried on dynamo 
housing. 

Either of the two dynamos shown at 
the left may be used. Either type of 
combination switch may be used. 

D12 


Drawing 




INTERNAL WIRING DIAGRAMS 


295 









































296 


STARTING AND LIGHTING TROUBLES 


DETROIT WARD LEONARD Separate Dynamo. 

Units Dynamo : Shunt wound, two field coils, 

two brushes. 

Controller: Ward Leonard type * 1 CC. ’’ 
Contains combined cut-out and cur¬ 
rent regulator. 

Voltage 6 

Output 10 amperes. 

Regulation Vibrating regulator inserting field re¬ 
sistance. Operated from same mag¬ 
net as used for cut-out. Lower con¬ 
tacts are for regulation. See sections 
421 and 429 to 431. 

Cut-out Electromagnetic combined with regu¬ 
lator. Upper contacts are for cut¬ 

out. 

DW1 


Drawing 


INTERNAL WIRING DIAGRAMS 


297 








































298 


STARTING AND LIGHTING TROUBLES 


DETROIT WARD LEONARD Motor-Dynamo. 

Units Motor-Dynamo : Shunt and series wind¬ 

ings, four field coils, four brushes. 

Controller: Wand Leonard type ‘ ‘ CD. * ’ 
Contains combined cut-out and cur¬ 
rent regulator with resistance 
mounted on outside. 

Voltage 6 

Output 10 amperes. 

Regulation Vibrating regulator inserting field re¬ 
sistance. Operated from same mag¬ 
net as used for cut-out. Lower con¬ 
tacts are for regulation. See sections 
421 and 429 to 431. 

Cut-out Electromagnetic combined with regu¬ 
lator. Upper contacts are for cut¬ 

out. 

DW2 


Drawing 


INTERNAL WIRING DIAGRAMS 


299 






























































300 


STARTING AND LIGHTING TROUBLES 


DISCO 

Units 


Voltage 

Output 

Regulation 


Cut-out 


Motor-Dynamo. 

Motor-Dynamo : Shunt and series wind¬ 
ings, four field coils, two brushes. 

Controller: Ward Leonard type ‘‘CD.’’ 
Contains combined cut-out and regu¬ 
lator without outside resistance. 

12 

5 to 6 amperes. 

Vibrating regulator inserting shunt 
field resistance. Operated from same 
electromagnet as used for cut-out. 
Double contacts at bottom for regu¬ 
lation. See sections 421 and 429 to 
431. 

Electromagnetic combined with regu¬ 
lator. Upper contacts are for cut¬ 
out. 

Z1 


Drawing 


INTERNAL WIRING DIAGRAMS 



JHO ^”3 























































302 


STARTING AND LIGHTING TROUBLES 


DISCO 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Separate Units. 

Dynamo : Shunt wound, four field coils, 
two main brushes and one regulating- 
brush. 

Motor: Series wound, four field coils, 
two brushes. 

Cut-out: Electromagnetic, separate 

unit. 

12 

6 amperes. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Electromagnetic. Separate unit. 

Z2 


INTERNAL WIRING DIAGRAMS 


308 
























304 STARTING AND LIGHTING TROUBLES 


DYNETO 

Units 


Voltage 

Output 

Regulation 

Cut-out 


Drawing 


Motor-Dynamo, Four Terminal, Re¬ 
versed Series. 

Motor-Dynamo : Shunt and series winch 
ings, six field coils. 

Starting Switch: Contains main start¬ 
ing contacts and also contacts which 
open field circuit, 

12 

12 amperes maximum. 

Reversed series field while generating. 
See section 461. 

Manual, by means of starting switch 
which makes permanent connection 
between motor-dynamo and battery 
for starting and charging functions. 

DY1 


INTERNAL WIRING DIAGRAMS 


303 































306 


STARTING AND LIGHTING TROUBLES 


DYNETO 

Units 


Voltage 

Output 

Regulation 

Cut-out 


Drawing 


Motor-Dynamo, Third Brush Type. 

Motor-Dynamo : Shunt and series wind¬ 
ings, six field coils. 

Starting Switch: Contains main start¬ 
ing contacts and also contacts which 
open field circuit. 

12 

8 to 9 amperes maximum. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Manual, by means of starting switch 
making permanent connection be¬ 
tween motor-dynamo and battery for 
starting and charging functions. 

Four terminal machine, DY2 


INTERNAL WIRING DIAGRAMS 


307 




V 






































308 STARTING AND LIGHTING TROUBLES 

DYNETO Motor-Dynamo, Third Brush Type. 

Units Motor-Dynamo: Shunt and series wind¬ 

ings, six field coils. 

Starting Switch: Contains main start¬ 
ing contacts and also contacts which 
open field circuit. 

Voltage 12 

Output 8 to 9 amperes maximum. 

Regulation Third brush for field current. See sec¬ 
tions 413 to 419. 

Cut-out ! Manual, by means of starting switch 

making permanent connection be¬ 
tween motor-dynamo and. battery for 
starting and charging functions. 
Three terminal machine, DY3 


Drawing 



Series \ -Lc) qY3 


INTERNAL WIRING DIAGRAMS 


309. 




























310 


STARTING AND LIGHTING TROUBLES 


DYNETO 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Separate Units.- 

Dynamo: Shunt wound, four field coils, 
two main brushes and one regulating 
brush. 

Cut-out: Electromagnetic; separate or 
on dynamo housing. 

Motor: Series wound, four field coils, 
four brushes. 

6 

12 amperes maximum. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Electromagnetic. Carried on top of 
dynamo or as separate unit. 

DY4 


INTERNAL WIRING DIAGRAMS 


3U 



Cut Out 









!___ 


j-tCJ 


Starting 
Switch 



DVi 






































312 


STARTING AND LIGHTING TROUBLES 


ENTZ 

Units 


Voltage 

Output 

Regulation 

Cut-out 


Motor-Dynamo. 

Motor-Dynamo : Shunt and series wind¬ 
ings, two field coils, four brushes. 

Starting Switch: Knife type. Contains 
main contacts to connect battery 
with motor-dynamo brushes and 
series field, auxiliary contact for 
shunt field circuit and additional 
contacts for control of ignition cir¬ 
cuit. 

18 for starting and charging, 6, 12 and 
18 for lighting. 

13 amperes maximum at 18 volts. 

Reversed series field while generating. 
See section 461. 

Manual, by means of starting switch 
making permanent connection be¬ 
tween motor-dynamo and battery 
for starting and charging functions. 

El 


Drawing 


INTERNAL WIRING DIAGRAMS 


313 






















































314 


STARTING AND LIGHTING TROUBLES 


ESTERLINE Four Terminal Dynamo. 

Units Dynamo: Permanent magnets together 

with shunt winding, reversed series 
winding and. load winding. Single 
field coil, two brushes. 

Fuse Panel: Carries lighting circuit 
fuses and cut-out. 


Voltage 6 

Output 10 to 12 amperes with lamps off. With 

lamps on, the output is 15 amperes. 

Regulation Reversed series field winding. Load 

winding carries charging current to 
battery and acts with reversed series 
winding. Current that passes direct 
to lamps does not pass through load 
winding and a higher output is then 
allowed-. Section 461. 

Cut-out Electromagnetic carried on fuse panel. 

Has additional set of contacts which 
open shunt circuit on cut-out magnet. 


Drawing Q1 





INTERNAL WIRING DIAGRAMS 


315 


V. 




1_ 





















































310 


STARTING AND LIGHTING TROUBLES 


ESTERLINE Two Terminal Dynamo. 

Units Dynamo: Permanent magnets together 

with shunt and reversed series field 
windings. Single field coil, two 
brushes. 

Fuse Panel: Carries lighting fuses and 
cut-out. 

Voltage 6 

Output 10 to 12 amperes. 

Regulation Reversed series field winding. See sec¬ 
tion 461. 

Cut-out Electromagnetic carried on fuse panel. 

Has additional set of contacts which 

open shunt circuit on cut-out magnet. 

Q2 


Drawing 



INTERNAL WIRING DIAGRAMS 


317 






























































318 


STARTING AND LIGHTING TROUBLES 


FORD 

Units 


Voltage 

Output 

Regulation 

Cut-out 


Fuses 


Liberty System. 

Dynamo : Shunt wound, four field coils, 
two main brushes and one regulating 
brush. 

Cut-out: Electromagnetic; separate 

unit or on dynamo. 

Motor: Series wound, four field coils, 
four brushes. 

6 

10 to 12 amperes maximum. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Electromagnetic. Cut-out carried on 
dash in early models, but later 
mounted on top of dynamo housing. 

Main fuse on dash in earlier models. 
None on later cars. 

Separate cut-out, FI. 


Drawing 


INTERNAL WIRING DIAGRAMS 


319 







































320 


STARTING AND LIGHTING TROUBLES 


FORD 

Units 


Voltage 

Output 

Regulation 

Cut-out 


Liberty System. 

Dynamo: Shunt wound, four field coils, 
two main brushes and one regulating 
brush. 

Cut-out: Electromagnetic; separate 
unit or on dynamo. 

Motor: Series wound, four field coils, 
four brushes. 

6 

10 to 12 amperes maximum. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Electromagnetic. Cut-out carried -on- 
dash in early models, but later 
mounted on top of dvnamo housing. 

Cut-out on dynamo, F2. 


Drawing 




internal wiring diagrams 


321 





























STARTING AND LIGHTING TROUBLES 


322 


GARFORD 

Units 


Voltage 

Output 

Regulation 

\ 

Cut-out 

Fuses 

Drawing 


Separate Dynamo. 

Dynamo: Shunt and reversed series 
windings, single field coil, two 
brushes. Cut-out contained in dyna¬ 
mo housing above commutator. 

Lighting Switch: Contains lighting 
switch, 10 ampere lighting fuse, dim¬ 
mer resistance and indicating target 
which shows cut-out closing and flow 
of charging current. 

6 

5 to 6 amperes maximum. 

Reversed series field winding. See sec¬ 
tion 461. 

Electromagnetic, carried in dynamo 
housing over commutator. 

Lighting fuse, 10 ampere, in lighting 
switch. 

II. 


\ 

5 


INTERNAL WIRING DIAGRAMS 


323 








































324 


STARTING AND LIGHTING TROUBLES 


GRAY & DAVIS Constant Speed Dynamo, 1913. 

Units Dynamo: Compound Avound^ tAvo field 

coils, tAvo brushes. 

Cut-out: Electromagnetic in separate 
unit. 

Motor: Series Avound. 

Starting SAvitch: Double contact Avith 
resistance in series on first contact. 

Voltage 6 

Output 8 amperes Avith charged battery. 

Regulation Dynamo speed maintained constant by 

slipping clutch governor, thus pro¬ 
ducing constant voltage above cer¬ 
tain speed. See sections 440, 442 and 
443. 

Cut-out Electromagnetic carried as separate 

unit. 

Drawing G1 



INTERNAL WIRING DIAGRAMS 


325 





















































326 STARTING AND LIGHTING TROUBLES 

GRAY & DAVIS Constant Speed Dynamo, 1914. 

Units Dynamo: Compound wound, two field 

coils, two brushes. 

Cut-out: Electromagnetic in separate 
unit. 

Motor: Series wound, with single con¬ 
tact switch. 

Voltage 6 

Output 8 amperes with charged battery. 

Regulation Dynamo speed maintained constant by 

slipping clutch governor, thus pro¬ 
ducing constant voltage above cer¬ 
tain speed. See sections 440, 442 
and 443. 

Cut-out Electromagnetic carried as separate 

unit. 

Fuses Lighting and accessory line fuses on 

lighting switch. 

G2 


Drawing 


INTERNAL. WIRING DIAGRAMS 


327 















































STARTING AND LIGHTING TROUBLES 



GRAY & DAVIS Vibrating Regular System, 1915. 

Units Dynamo: Shunt wound, two field coils, 

two brushes. 

Controller: Mounted on top of dynamo. 
Contains cut-out and regulator. 

Motor: Series wound. 

Starting Switch: Single contact. 

Voltage 6 

Output Model “S,” 9!/2 amperes; model “T,” 

8 amperes. Both outputs taken 
with lamps turned off and charged 
battery. 

Regulation Constant amperage maintained by vi¬ 
brating relay inserting shunt field 
resistance. Turning lamps on reduces 
flow of current through series wind¬ 
ing of relay electromagnet and allows 
increased output. See sections 421, 
423 and 429 to 431. 


Out-out Electromagnetic combined with current 

regulator and carried on top of dy- 
. namo. 

Fuses Lighting and accessory line fuses on 

lighting switch. 

Drawing G3 


t 




INTERNAL WIRING DIAGRAMS 


829 




















































330 STARTING AND LIGHTING TROUBLES 

GRAY & DAVIS Vibrating Regulator System, 1916. 

Units Dynamo : Shunt wound, two field coils, 

two brushes. 

Controller: Mounte-d on top of dynamo. 
Contains cut-out and regulator. 

Motor: Series wound. 

Starting Switch : Single contact. 

Voltage 6 

Output 10 amperes with lamps turned off and 

charged battery. 

Regulation Constant amperage maintained by a 

vibrating relay inserting shunt field 
resistance. Turning lamps on reduces 
flow of current through series wind¬ 
ing of relay electromagnet and allows 
increased output. See sections 421, 
423 and 429 to 431. 

Cut-out Electromagnetic combined with regu¬ 

lator on top of dynamo. 

Fuses Lighting and accessory line fuses on 

lighting switch. 

Drawing G4 . 



INTERNAL WIRING DIAGRAMS 


331 










































332 STARTING AND LIGHTING TROUBLES 

GRAY & DAVIS Third Brush System. 

Units Dynamo : Shunt wound, two field coils, 

two main brushes and one regulating 
brush. Cut-out carried in dynamo 
housing. 

Motor: Series wound with single con¬ 
tact starting switch. 

Voltage 6 

Output 14 to 17 amperes maximum. 

Regulation Third brush for shunt field current. See 

sections 413 to 419. 

Out-out Electromagnetic, carried in dynamo 

housing. 

Fuses Lighting and accessory line fuses car¬ 

ried on lighting switch. 

Remarks Either of the lighting switches shown 

at the top of the drawing may be 
used). 

G5 


Drawing 


INTERNAL. WIRING DIAGRAMS 


333 





L/ghfing 

Switch 


Starting j~-| 
Sw/tcn s L _4 j 

if )■ 

t.^M _ ~~ 



























































334 


STARTING AND RIGHTING TROUBLES 


GRAY & DAYIS Motor-Dynamo. 

Units Motor-Dynamo: Shunt and series wind¬ 

ings, two field coils, two brushes. 

Controller: Mounted on top of motor- 
dynamo. Contains cut-out and regu¬ 
lator. 

Starting Switch: Single contact. 

Voltage 6 

Output 8 to 10 amperes with charged battery. 

Regulation Constant amperage maintained by vi¬ 
brating relay inserting shunt field 
resistance. See sections 421 and 429 
to 431. 

Cut-out Electromagnetic combined with current 

regulator and carried on top of 
motor-dynamo. 

Fuses Main line fuse connected as shown on 

drawing. 

Drawing G6 


( 


INTERNAL WIRING DIAGRAMS 


335 

















































336 


STARTING AND RIGHTING TROUBLES 


HARTFORD 

Units Dynamo: Shunt wound, constant speed 

type. 

Dash Unit: Contains cut-out, ammeter 
and voltmeter.. 

Motor: Series wound. 

Voltage 12 for charging and starting. 6 for 

lighting. 

Output 7 to 8 amperes with normally charged 

battery. 

Regulation Dynamo driven at constant speed by 

means of slipping clutch governor, 
thus generating practically constant 
voltage above speed at which clutch 

releases. See sections 440 and 442. 

Cut-out Electromagnetic mounted between volt¬ 

meter and ammeter on dash unit. 

Drawing Ml 


INTERNAL WIRING DIAGRAMS 


337 




L/ghf/ng 

Swifc/j 



■N 


*\ 





• (fl? 

5ferhng x \ , J 
Switch !—jj 























































338 


STARTING AND LIGHTING TROUBLES 


HEINZE 

Units 


Voltage 

Output 

Regulation 


Cut-out 


Double Deck, External Controller. 

Motor and Dynamo : Double deck type; 
motor on top, dynamo below. 

Dynamo: Shunt wound, four field coils, 
two brushes. Motor, series wound, 
four field coils, two brushes. 

Controller: Mounted on top of motor 
and dynamo. Contains vibrating 
regulator and electromagnetic cut¬ 
out. 

Lighting and Ignition Switch: Con¬ 
tains lighting and ignition contacts, 
also dimmer resistance. 

6 

10 amperes. 

Field resistance controlled by vibrat¬ 
ing relay operated from same magnet 
that operates cut-out. See sections 
421 and 429 to 431. 

Electromagnetic in controller above 
motor and dynamo. Operates from 
same magnet that actuates regulator 
contacts. 

HI 


Drawing 


INTERNAL WIRING DIAGRAMS 


339 













































340 


STARTING AND LIGHTING TROUBLES 


HEINZE 

Units 


Voltage 

Output 

Regulation 

• 

Cut-out 


Drawing 

i 


Double Deck, Reversed Series Machine. 

Motor and Dynamo: Double deck type, 
motor on top, dynamo below. 

Dynamo: Shunt and reversed series 
windings, four field coils, two 
brushes. Motor: four field coils, 
series wound, two brushes. Start¬ 
ing switch on motor frame. 

Lighting and Ignition Switch: Con¬ 
tains lighting and ignition contacts, 
also dimmer resistance. 

6 

12 amperes maximum. 

Reversed series field winding. See sec¬ 
tion 461. 

Manual by means of additional contacts 
interconnected with ignition switch 
control. 


i 

f 





INTERNAL WIRING DIAGRAMS 


341 

































342 


STARTING AND LIGHTING TROUBLES 


JESCO 

Units 


Voltage 

Output 

Regulation 

Cut-out 


Motor-Dynamo, Separate Controller 
and Switch, 1913. 

Motor-Dynamo : Shunt, reversed series 
and starting series wound, four field 
coils, two brushes. 

Controller: Usually mounted on heel 
board. Rotary drum lighting switch 
at top; starting contacts below light¬ 
ing switch; cut-out below starting 
contacts; regulator below cut-out and 
output control lever on bottom of 
unit. 

8 for charging, 16 for starting. 

13 amperes maximum. 

Resistance and regulator contacts in 
parallel with reversed series field 
winding. Opening of these contacts 
sends current through reversed series 
field winding. See section 473. 

Electromagnetic in controller housing. 
Carries additional contacts which 
close with cut-out and light pilot 
lamp. 

J1 


Drawing 


INTERNAL WIRING DIAGRAMS 


343 















































































































344 


STARTING AND LIGHTING TROUBLES 


JESCO 

Units 


Voltage 

Output 

Regulation 


Cut-out 

Drawing 


Motor-Dynamo with Controller on Top 
of Housing, 1914. 

Motor-Dynamo : Shunt, reversed series 
and starting series windings, four 
field coils. Two sets of brushes; four 
for starting and two for generating 
functions. 

Controller: Single magnet with series 
and shunt windings. Cut-out con¬ 
tacts at one end and regulator con¬ 
tacts at other end. Resistance car¬ 
ried on magnet core. Starting con¬ 
tacts in controller housing. 

6 

9 to 14 amperes. 

Resistance winding and regulator con¬ 
tacts in parallel with reversed series 
field winding. Opening of these con¬ 
tacts sends current through reversed 
series field winding. See section 474. 

Electromagnetic. With regulator on 
dynamo housing. 

J2 


INTERNAL WIRING DIAGRAMS 


345 



































































346 STARTING AND LIGHTING TROUBLES 

JESCO Tandem Motor and Dynamo, 1915 and 

1916. 

Units Dynamo: Shunt and reversed series 

field windings, four field coils, two 
brushes. 

Motor: Series and starting windings 
cn fields, four field coils, three 
brushes. One brush used as starting 
switch. Preliminary starting field 
circuit closed through contacts on 
top of motor. 

Controller: Single magnet carrying 
series winding, shunt winding and 
resistance coil. Cut-out contacts at 
one end, regulator contacts at other 
end. 

Voltage 6 

Output 8 to 14 amperes. 

Regulation Resistance winding and regulator con¬ 

tacts in parallel with reversed series 
field. Opening of these contacts sends 
current through reversed series field 
winding. See section 474. 

Cut-out Electromagnetic. With regulator on 

dynamo housing. 

J3 


Drawing 


INTERNAL. WIRING DIAGRAMS 


347 

















































STARTING AND LIGHTING TROUBLES 


348 

LEECE NEVILLE 1913, 12 Volt. 

Units Dynamo : Shunt wound, two field coils, 

two main brushes and one regulating 
brush. 

Cut-out: Electromagnetic, mounted as 
separate unit. 

Motor: Series wound. 

Starting Switch: Single contact, two 
pole, sliding contact type. Breaks 
both sides of starting circuit. 

Voltage 12 

Output 12 amperes maximum. 

Regulation Third brush for field current. See 

sections 413 to 419. 

Cut-out Electromagnetic of two pole type, 

breaking both sides of charging cir¬ 

cuit by means of two separate pairs 
of contacts. Auxiliary points on each 
set of contacts take spark as circuit 
is broken. 

Drawing LI 


i 




INTERNAL WIRING DIAGRAMS 


349 









































350 STARTING AND LIGHTING TROUBLES 

LEECE NEVILLE 1914, 6 Volt. 

Units Dynamo : Shunt wound, four field coils, 

two main brushes and one regulat¬ 
ing brush. 

Cut-out: Electromagnetic, mounted as 
separate unit. 

Motor: Series wound. 

Starting Switch: Single contact, two 
pole, rotary type. Breaks both sides 
of starting circuit. 

Voltage 6 

Output 16 amperes. 

Regulation Third brush for field current. See sec¬ 

tions 413 to 419. 

Cut-out Electromagnetic of two pole type, 

breaking both sides of charging cir¬ 
cuit by means of two separate pairs 

of contacts. Auxiliary points on 
each set of contacts which take spark 
as circuit is broken. 

L2 


Drawing 


INTERNAL WIRING DIAGRAMS 


351 










































352 STARTING AND LIGHTING TROUBLES 

t 

LEECE NEVILLE Cut-out on Dynamo. 

Units Dynamo : Shunt wound, four field coils, 

two main brushes and one regulat¬ 
ing brush. 

Cut-out: Electromagnetic mounted* on 
top of dynamo. Field fuse on cut¬ 
out. 

Voltage 6 

Output 15 amperes. 

Regulation Third brush for field current. See sec¬ 
tions 413 to 419. 

Cut-out Electromagnetic mounted on top of 

dynamo. 

Fuses Field fuse carried in cut-out housing. 

Drawing L3 



INTERNAL. WIRING DIAGRAMS 


QX*> 

oOo 


Cut Out 

ro cQ 


0=0 Field 


Fuse 


\ \ i -— 


' Connecting 


To Battery 






















354 STARTING AND LIGHTING TROUBLES 

NORTH EAST Motor-Dynamo, Model “A,” 16 Volt. 

Units Motor-Dynamo: Shunt and series 

wound, four field coils, two brushes. 
Cut-out, current regulator and field 
fuse carried in motor-dynamo hous¬ 
ing. 

Voltage 16 for charging and starting, 8 for 

lighting. 

Output 6 amperes. 

Regulation Vibrating relay, inserting field resist¬ 

ance, maintains constant current 
above certain speed. Regulating unit 
separate from cut-out. See sections 
421 and 429 to 431. 

Cut-out Electromagnetic carried in motor- 

dynamo housing. Not combined with 
regulator. 

Fuses Field fuse carried in motor-dynamo 

housing. 

Drawing N1 


INTERNAL WIRING DIAGRAMS 355 



lighting 

Switch 


\ 

\ 




















































































356 


STARTING AND LIGHTING TROUBLES 

NORTH EAST Motor-Dynamo, Model “£,”16 Volt. 

Units Motor-Dynamo: Shunt and series 

wound, four field coils, two brushes. 
Cut-out, current regulator, condenser 
and field fuse carried in motor-dy¬ 
namo housing. 

Voltage 16 for charging and starting, 8 for 

lighting. 

Output 6 amperes. 

Regulation Vibrating relay, inserting field resist¬ 
ance, maintains constant amperage 
above certain speed. Regulating unit 
separate from cut-out. See sections 
421 and 429 to 431. 

Cut-out Electromagnetic carried in motor-dy¬ 

namo housing. Not combined with 
regulator. 

Fuses Field fuse carried in motor-dynamo 

housing. 

Drawing N2 



INTERNAL WIRING DIAGRAMS 


357 



Lighting 

Switch 














































































358 


STARTING AND RIGHTING TROUBLES - 


NORTH EAST Motor-Dynamo, Models “D” and 

“E.” 


Units 

Motor-Dynamo: Shunt and series 

wound, four field coils, two brushes. 
Cut-out, current regulator, condenser 
and field fuse carried in motor-dy¬ 

Voltage 

namo housing. 

Model “D,” 24 volts for charging and 
starting, 6 or 12 volts for lighting. 
Model “E,” 24 or 12 volts for charg¬ 
ing and starting, 6 or 12 volts for 
lighting. 

Output 

5 amperes at 24 volts. 8 amperes at 12 
volts. 

Regulation 

Vibrating relay, inserting field resist¬ 
ance, maintains constant amperage 
above certain speed. Regulating unit 
separate from cut-out. See sections 
421 and 429 to 431. 

Cut-out 

Electromagnetic, carried in motor-dy¬ 
namo housing. 

Fuses 

Field fuse carried in motor-dynamo 
housing. 

Drawing 

N3 


INTERNAL WIRING DIAGRAMS 


359 




Switch 



Field | 


f 



Resist¬ 

ance 











































































360 STARTING AND LIGHTING TROUBLES 

NORTH EAST Motor-Dynamo, Model “G,” 12 Volt. 

Units Motor-Dynamo: Shunt and series 

wound, four field coils, two main 
brushes and one regulating brush. 
Field fuse in motor-dynamo housing. 

Starting Switch Unit: Contains single 
contact starting switch and cut-out. 

Voltage 12 

Output 7 amperes. 

Regulation Third brush for field current. See sec¬ 

tions 413 to 419. 

Cut-out Electromagnetic, carried in starting 

switch unit. 

Fuses Field fuse carried in motor-dynamo. 

Drawing N4 


internal wiring diagrams 


861 • 






















362 STARTING AND LIGHTING TROUBLES 


NORTH EAST Separate Units, Models “L” and 

i < > » 


Units Dynamo: Shunt wound, two field coils, 

two main brushes and one regulating 
brush. Field fuse on dynamo hous¬ 
ing. See “ Remarks,” below, for ex- 
; , planation of drawing. 

Cut-out: Electromagnetic carried as 
separate unit. 

Motor: Series wound, four field coils, 
four brushes. 

Starting Switch: Single contact. 

Voltage Model “L,” 6 or 12 volts. Model “P,” 

12 volts. 

Output Model “L,” 6 volt, 16 amperes max¬ 
imum. 

Model “L, ” 12 volt, 8 V 2 amperes max¬ 
imum. 

Model “P,” 12 volt, 15 amperes max¬ 
imum. 

Regulation Third brush for field current. For ex¬ 
planation of brush position see “Re¬ 
marks,” below. See sections 413 to 
419. 


Cut-out 

Fuses 

Remarks 


Drawing 


Electromagnetic carried as separate 
unit. 

Field fuse on dynamo housing. 

Full lines in drawing show anti-clock¬ 
wise rotation from commutator end. 
Dotted lines show clockwise rotation 
from commutator end. 

N5 


INTERNAL WIRING DIAGRAMS 


363 





























364 


STARTING AND LIGHTING TROUBLES 


REMY 

Units 


Voltage 

Output 

Regulation 


Cut-out 

Fuses 

Drawing 


Separate Dynamo, Model “M.” 

Dynamo: Shunt, reversed series and 
load windings, single field coil, two 
brushes. Cut-out carried on dynamo. 

Dash Unit: Contains lighting switch 
and lighting line fuses. 

12 for charging, 12 or 6 for lighting. 

5 y 2 amperes maximum. 

Reversed series field winding. With 
the lamps turned on, the current flow 
is reduced through a part of the re¬ 
versed series winding and the output 
is thereby allowed to increase. See 
section 461. 

Electromagnetic carried on dynamo. 

Lighting line fuses carried on dash unit. 
R1 


INTERNAL WIRING DIAGRAMS 


365 















































































366 


STARTING AND LIGHTING TROUBLES 


REMY 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Fuses 

Drawing 


Ignition Dynamos, Models “ 0, ” ‘ * OB, ’ ’ 
“11,” “17,” Etc. 

Ignition-Dynamo : Shunt wound, single 
field coil, two main brushes and one 
regulating brush. Ignition breaker 
and distributor of magneto type 
mounted on dynamo and driven from 
armature shaft. Field fuse in cut¬ 
out. 

Motor: Series wound, four field coils, 
four brushes. 

Starting Switch: Single contact, slid¬ 
ing type. 

6 

16 amperes maximum. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Electromagnetic carried on dynamo. 
Field fuse mounted on cut-out. 

Field fuse carried on cut-out. Others 
to suit car. 

R2 


INTERNAL WIRING DIAGRAMS 






































































368 


STARTING AND LIGHTING TROUBLES 


REMY 

Units 


Voltage 

Output 

Regulation 


Cut-out 

Fuses 

l 

Drawing 


Motor-Dynamo, Model 41 129.” 

Motor-Dynamo: Shunt and series 

windings, four field coils, four 
brushes. 

Controller: Contains combined cut-out 
and regulator and carries field fuse. 

Starting Switch: Single contact type. 

12 

7 j /2 amperes. 

Vibrating relay inserts field resistance 
to maintain constant amperage above 
certain speed. See sections 421 and 
429 to 431. 

Electromagnetic combined with regu¬ 
lator in controller housing. 

Field fuse carried on controller base. 

Others to suit car. 

R3 



INTERNAL WIRING DIAGRAMS 


369 



r. 


re/d Fuse 


r* 


r Feg. 


Condenser 


“VWVnWWV 


Senes 


Resistance 










V. 


































































370 


STARTING AND LIGHTING TROUBLES 


REMY 

Units 


Voltage 

Output 

Regulation 


Cut-out 

Fuses 

Drawing 


Double Deck Machine, External Regu¬ 
lator, Model “150,” Etc. 

Motor {Mid Dynamo: Single frame car¬ 
rying motor on top and dynamo be¬ 
low. 

Dynamo: Shunt wound, two field coils, 
four brushes. Motor, series wound, 
two field coils, four brushes. 

Controller: Contains combined cut-out 
and regulator and carries field fuse. 

Starting Switch: Single contact type. 

6 

12 amperes. 

Vibrating relay inserts field resistance 
to maintain constant amperage above 
certain speed. See sections 421 and 
429 to 431. 

Electromagnetic combined with regu¬ 
lator in controller housing. 

Field fuse carried on controller base. 
Others to suit car. 

R4 


INTERNAL WIRING DIAGRAMS 


371 






5 witch 













































372 


STARTING AND LIGHTING TROUBLES 


REMY 

Units 

I 

t 

f 

i 


Voltage 

Output 

Regulation 

Cut-out 

Ruses j 

i i 

Drawing 

i i- 

\ 

? 


Double Deck, Third Brush Machine, 
Model “SL,” Etc. 

Motor and Dynamo: Single frame car¬ 
rying motor on top and dynamo be¬ 
low. 

Dynamo: Shunt wound, two field coils, 
two main brushes and one regulating 
brush. Motor: Series wound), two 
field coils, four brushes. 

Cut-out: Electromagnetic carried as 
separate unit. Field fuse on cut-out. 

Starting Switch: Single contact type. 

6 

i 14 amperes maximum. 

Third brush for field current. See sec- 

i tions 413 to 419. 

j Electromagnetic carried as separate 
unit. 

i 

I Fijeld fuse carried on cut-out base. 

1 Others to suit car. 

: _ _ 


i / 

i 

I 

i 

\ 

I 

t 



INTERNAL WIRING DIAGRAMS 


373 





































374 STARTING AND LIGHTING TROUBLES 


REMY 

Units 


Voltage 

Output 

Regulation 


Cut-out 

Fuses 

Drawing 


Separate Units, External Controller. 

Dynamo: Shunt wound, four field coils, 
two main brushes and one regulat¬ 
ing brush. 

Controller: Contains combined cut-out 
and regulator and carries field fuse. 

Motor: Series wound, four field coils, 
four brushes. 

Starting Switch: Single contact type. 

6 

11 to 12 amperes. 

Vibrating relay inserting field resist¬ 
ance to maintain constant amperage 
above certain speed. See sections 421 
and 429 to 431. 

Electromagnetic combined with regu¬ 
lator in controller housing. 

Field fuse on controller base. Others 
to suit car. 


INTERNAL WIRING DIAGRAMS 


375 



Resistance 


































376 


STARTING AND LIGHTING TROUBLES 


REMY 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Separate Units, Third Brush Dynamo. 

Dynamo : Shunt wound, four field coils, 
two main brushes and one regulating 
brush. 

Cut-out: Electromagnetic, carried as 
separate unit or on dynamo housing. 

Motor: Series wound, four field coils, 
four brushes. 

Starting Switch: Single contact type. 

6 

14 to 15 amperes maximum. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Electromagnetic carried as separate 
unit or on dynamo housing. 

R7 




































378 


STARTING AND LIGHTING TROUBLES 


REMY 

Units 


Voltage 

Output 

Regulation 


Cut-out 

Remarks 


Separate Units, Third Brush Dynamo 
With Thermostat. 

Dynamo: Shunt wound, two field coils, 
two main brushes and one regulating 
brush. Regulating thermostat car¬ 
ried in dynamo. 

Cut-out: Electromagnetic mounted on 
dynamo or separate. 

Motor: Series wound, four field coils, 
four brushes. 

Starting Switch: Single contact type. 

6 

18 to 20 amperes when cold. 13 to 14 
amperes after dynamo heats suffi¬ 
ciently to open thermostat contacts. 

Third brush for field current as ex¬ 
plained in sections 413 to 419. This 
machine is also equipped with a ther¬ 
mostat whose action is explained in 
section 462. 

Electromagnetic, carried as separate 
unit. 

The thermostat also acts as a field fuse, 
in that its resistance will burn out 
with excessive flow of field current. 
R8 


Drawing 


INTERNAL, WIRING DIAGRAMS 


379 






























380 


STARTING AND LIGHTING TROUBLES 


REMY 

Units 


Voltage 

Output 


Regulation 


Cut-out 

Drawing 


Separate Units, Thermostat Controlled 
Dynamo. 

Dynamo: Shunt wound, four field coils, 
four brushes. Controller contains four 
thermostat blades and resistances. 

Cut-out: Electromagnetic carried as 
separate unit. 

Motor: Series wound, two field coils, 
four brushes. 

Starting Switch: Single contact type. 

6 or 12 

6 to 25 amperes at 6 volts, the rate •de¬ 
pending on the dynamo temperature 
and on the number of thermostat con¬ 
tacts that have opened. As dynamo 
heats, successive thermostat contacts 
open and insert their resistance, 
which lowers the output. At 12 volts 
the rate is about one-half the above. 

Field current passes through contact 
points of four thermostats. Between 
these contacts are resistances con¬ 
nected in parallel with the contacts 
so that, with the contacts open, the 
field current must flow through the 
resistance. All contacts are closed 
with the dynamo cold, thus allowing 
unrestricted field current and high 
output. Increasing heat opens suc¬ 
cessive thermostats and the resulting 
field resistance reduces the output. 

Electromagnetic, separate unit. 

R9 


INTERNAL WIRING DIAGRAMS 


381 




Cut Out 









































382 


STARTING AND LIGHTING TROUBLES 


REMY 

Units 


Voltage 

Output 

Regulation 

Cut-out 


Puses 

Drawing 


Motorcycle Ignition-Dynamo. 

Ignition-Dynamo : Shunt wound, single 
field coil, two main brushes and one 
regulating brush. Ignition from bat¬ 
tery current with breaker and mov¬ 
ing arm timer carried on dynamo. 
Two ignition coils mounted on top of 
dynamo. 

Controller: Contains the vacuum cut¬ 
out, the lighting switch, the horn fuse 
and the lighting fuse. 

6 

4V 2 amperes maximum. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Vacuum type, having its contacts closed 
by the vacuum produced in the in¬ 
take manifold of the engine when 
the machine is started. Carried in 
the controller. 

Horn fuse and lighting fuse carried in 
controller. 

RIO 




F/e/d Co/7 


INTERNAL WIRING DIAGRAMS 


383 






£ 

* 

"i 

•i 



Regulating 

Brush 



/ 



















































:584 


STARTING AND LIGHTING TROUBLES 


REMY 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Fuses 

Drawing 


Motorcycle Dynamo Without Ignition. 

Dynamo : Shunt wound, two field coils, 
two main brushes and one regulating 
brush. Centrifugal cut-out on dy¬ 
namo. 

Switch: Contains lighting switch and 
carries horn fuse and lighting fuse. 

6 

4 amperes maximum. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Centrifugal type carried outside the 
commutator end of dynamo. 

Lighting fuse and horn fuse carried on 
switch. 

Rll 




INTERNAL, WIRING DIAGRAMS 


385 










































386 


STARTING AND LIGHTING TROUBLES 


RUSHMORE Cut-out on Dynamo. 

Units Dynamo: Shunt and reversed series 

wound, two field coils, two brushes. 
✓ ' ' 

Cut-out on top of dynamo. 

Dash Unit: Contains regulating ballast 
coil, field fuse and head lamp switch. 
Motor: Series wound with double con¬ 
tact switch having resistance in cir¬ 
cuit on first contact. Shown on 
drawing 02. 


Voltage 

Output 

Regulation 

Cut-out 

Fuses 

Drawing 


6 

12 to 15 amperes with dash unit switch 
turned on. 4 to 6 amperes with dash 
unit switch turned off. 

Reversed series field winding having 
its current determined, by iron wire 
ballast coil. See section 4G3. 

Electromagnetic carried on top of dy¬ 
namo. 

Field fuse carried in dash unit. Main 
line fuse mounted separately. 

01, Starting motor and switch same as 
, on drawing 02. 



INTERNAL* WIRING DIAGRAMS 


387 






























































r 

888 STARTING AND LIGHTING TROUBLES 

RUSHMORE Separate Cut-out. 

Units Dynamo: Shunt and reversed series 


Voltage 

Output 

wound, two field coils, two brushes. 

Cut-out: Separate unit. May also 
carry ballast coil, charging fuse and 
field fuse. 

Motor: Series wound. 

Starting Switch: Double contact with 
resistance in circuit on first point. 

6 

12 to 15 amperes depending on ballast 
coil wire size. 

Regulation 

Reversed series field winding, having 
its current determined by iron wire 
ballast coil. See section 463. 

Cut-out 

Electromagnetic carried as separate 
unit. 

Fuses 

Charging fuse between dynamo and 
cut-out; field carried on cut-out or 
separately. Other fuses to suit car. 

Drawing 

02 




INTERNAL WIRING DIAGRAMS 


389 


\ 



l 














































300 


STARTING AND LIGHTING TROUBLES 


SIMMS HUFF Motor-Dynamo, 1915. 

Units Motor-Dynamo : Shunt and series wind¬ 

ings, six field coils, six brushes. 

Controller: Contains combined cut-out 
and current regulator. Mounted un¬ 
der front seat. 

Starting Switch: Commutating type, / 
sliding contacts. 

Voltage 6 for charging and lighting, 12 foi* k 

starting. 

Output 10 to 15 amperes, depending on adjust¬ 
ment. 

Regulation Vibrating relay inserts field resistance 

to maintain constant amperage above 4 
certain speed. Single electromagnet 
used for both regulator and cut-out. 
See sections 421 and 429 to 431. 

Cut-out Electromagnetic combined with current 

regulator. 

SHI 


Drawing 



INTERNAL WIRING DIAGRAMS 




























































392 


STARTING AND LIGHTING TROUBLES 


SIMMS HUFF Motor-Dynamo, 1916. 

Units Motor-Dynamo : Shunt and series wind- 


Voltage 

ings, six field coils, six brushes. 

Dash Unit: Contains combined current 
regulator and cut-out, lighting fuses, 
lighting switch and ammeter. 

Starting Switch: Commutating type. 

6 for charging and lighting, 12 for 
starting. 

Output 

10 to 14 amperes with charge switch in 
“HIGH” position, 9 amperes with 
switch in “LOW” position. 

Regulation 

Vibrating relay inserts fiel-d resistance 
to maintain constant amperage above 
certain speed. Single electromagnet 
used for both regulator and cut-out. 
See sections 421 and 429 to 431. 

Cut-out 

Electromagnetic, combined with current 
regulator in dash unit. 

Fuses 

Drawing 

Lighting line fuses carried in dash unit. 
SH2 



Starting Switch 


INTERNAL WIRING DLYGRAMS 


393 

























































































:'f)4 STARTING AND LIGHTING TROUBLES 

SIMMS HUFF Motor-Dynamo, 1917. 

Units Motor-Dynamo : Shunt and series wind 


Voltage 

ings, six field coils, six brushes. 

Dash Unit: Contains combined current 
regulator and cut-out, lighting fuses, 
lighting switch and dimmer resist¬ 
ance. 

Starting Switch : Commutating type. 

6 for charging and lighting, 12 for 
starting. 

Output 

Regulation 

10 to 12 amperes. 

Vibrating relay inserts field resistance 
to maintain constant amperage above 
certain speed. Single electromagnet 
used for both regulator and cut-out. 
See sections 421 and 429 to 431. 

Cut-out 

Electromagnetic, combined with cur¬ 
rent regulator in dash unit. 

Fuses 

Drawing 

Lighting line fuses carried in dash unit. 
SH3 






INTERNAL WIRING DIAGRAMS 


H95 



I Regulator 


















































































396 


STARTING AND LIGHTING TROUBLES 


SIMMS HUFF Motor-Dynamo, 1918 and 1919 
Units Motor-Dynamo: Shunt and series wind- 


Voltage 

Output 

Regulation 

ings, six field coils, six brushes. 

Dash Unit: Contains combined current 
regulator and. cut-out, lighting fuses, 
lighting switch and dimmer resist¬ 
ance. 

Starting Switch: Single contact type 
with release operated by solenoid 
energized from starting button. 

12 

6 to 7 amperes. 

Vibrating relay inserting field resist¬ 
ance to maintain constant amperage 
above certain speed. Single electro¬ 
magnet used for both regulator and 
cut-out. See sections 421 and 429 to 
431. 

Cut-out 

Electromagnetic, combined with cur¬ 
rent regulator in dash unit. 

Fuses 

Drawing 

Lighting line fuses carried in dash unit. 
SH4 


INTERNAL WIRING DIAGRAMS 


397 



/resistance 




































































308 


STARTING and lighting troubles 


SPLITDORF Motor-Dynamo, 6-12 Volt. 

Units Motor-Dynamo: Shunt, reverse-d series 

and starting* series windings, two 
field coils, four brushes. 

Cut-out: Electromagnetic carried as 
separate unit. 

Starting Switch: Commutating type 
giving 6 volts for charging and light¬ 
ing and 12 volts for starting. 

Voltage 6 for charging and lighting, 12 for 

starting. 

Output 13 amperes maximum. 

Regulation Reversed series field winding. See sec¬ 
tion 461. 

Cut-out Electromagnetic carried as separate 

unit. Indicating target on cut out. 

Fuses Lighting fuse may be carried on cut¬ 

out. 

SI 


Drawing 





INTERNAL WIRING DIAGRAMS 


399 



MD-^5 



3 + 




s i°>+ 



















































































400 


STARTING AND LIGHTING TROUBLES 


SPUTDORF Motor-Dynamo, 12 Volt. 

Units Motor-Dynamo: Shunt, reversed series 

and starting series windings, two 
field coils, four brushes. 

Cut-out: Electromagnetic carried as 
separate unit. 

Starting Switch: Single contact type. 

Voltage 12 for charging and starting. 

Output 8 amperes maximum. 

Regulation Reversed series field winding. See sec¬ 

tion 461. 

Cut-out Electromagnetic carried as separate 

unit. Indicating target on cut-out. 

Fuses Lighting fuse may be carried on cut- 

. out. 

Drawing S2 


V 



INTERNAL, WIRING DIAGRAMS 


401 






































402 


STARTING AND LIGHTING TROUBLES 


, SPLXTDORF Separate Dynamo. 

Units Dynamo : Shunt wound, two field coils, 

four brushes. 

Controller: Contains cut-out and cur¬ 
rent regulator. Mounted as separate 
unit. 

Voltage 6 

Output 7 to 10 amperes maximum. 

Regulation Vibrating relay inserts resistance in 

shunt field and maintains constant 
current above certain speed*. One 
electromagnet used for both regula¬ 
tor and cut-out. See sections 421 and 
429 to 431. 

Cut-out Electromagnetic, combined with cur¬ 
rent regulator and using same elec¬ 

tromagnet. 


Drawing 


internal wiring diagrams 


























401 


STARTING AND LIGHTING TROUBLES 


SPLITDORF Motorcycle Unit, Magneto-Dynamo. 

Units Magneto-Dynamo: Dynamo on top and 

magneto below. Dynamo shunt 
wound, two field coils, two brushes. 
Cut-out and regulator carried in dy¬ 
namo housing. 

Voltage G 

Output 3 amperes maximum. 

Regulation Centrifugally operated contacts act to 

insert field resistance above certain 
speed. 

Cut-out Centrifugal. Operated by same weights 

that act for regulation. Carried in 
dynamo housing. 

Fuses Main fuse mounted on fuse block. 

Remarks . A starting switch is provided whose 

closing causes the dynamo to act as 
a motor and, by energizing the fields 
from the storage battery, a hot start¬ 
ing spark is produced. 

S4 


Drawing 


INTERNAL WIRING DRVGRAMS 


405 


l 



Storting 

Button 



























STARTING AND LIGHTING TROUBLES 


•iOG 

SPLITDORF Motorcycle Unit, Separate Dynamo. 

Units Dynamo: Shunt wound, two field coils, 

two main brushes and one regulating 
brush. Cut-out in dynamo housing. 

Voltage 6 

Output 4% amperes maximum. 

Regulation Third brush for field current. See sec¬ 

tions 413 to 419. 

Cut-out Centrifugal, operated by governor with 

ring weight carriod on commutator 
end of dynamo. 

Fuses Lighting fuse in main lighting line. 

Drawing S5 


INTERNAL WIRING DIAGRAMS 


407 


























408 


STARTING AND LIGHTING TROUBLES 


SPUTDORF Constant Voltage Independent Dy¬ 
namo. 


Units 

Voltage 

Output 

Regulation 


Cut-out 

Remarks 


Drawing 


Dynamo : Shunt wound, two field coils, 
two brushes. Voltage regulator car¬ 
ried in dynamo. 

6 

Depends on load applied; normally 
about 7 to 8 amperes. 

Constant voltage maintained at 6 V 2 
above 1200 r.p.m. Cam carried on end 
of armature shaft opens regulator 
contacts at each revolution. The dis¬ 
tance apart of these contacts is de¬ 
termined by the pull of a voltage 
operated magnet so that, as voltage 
increases, the contacts are closed dur¬ 
ing less time. See section 477. 

None required. 

This dynamo is used for lighting only 
and without a storage battery. The 
voltage being constant, lamps may be 
operated whenever the dynamo runs 
at sufficient speed. 

S 6 


INTERNAL WIRING DIAGRAMS 

































410 


STARTING AND LIGHTING TROUBLES 


U. S. L. 


Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawings 


External Regulator, External Arma¬ 
ture. 

Motor-Dynamo : Flywheel type, shunt 
and series windings, eight field coils, 
eight brushes. 

Controller: Single magnet operates 

cut-out and carbon disc regulator. 

Touring Switch: Opens and closes, 
charging and field circuit. 

Starting Switch: Rotary drum com¬ 
mutating type. 

12 for charging and 24 for starting. 

10 to 12 amperes. 

Carbon disc field resistance. See sec¬ 
tion 465. 

Electromagnetic in controller. 

Motor-Dynamo U2 left; external cir¬ 
cuits Ul. 




INTERNAL, WIRING DIAGRAMS 


411 



I 

I 

I 

I 

( 

\ 

I 

I 

I 

I 

I 












































































112 


STARTING AND LIGHTING TROUBLES 


U. S. L. 
Units 


Voltage 

Output 

Regulation 

Out-out 

Drawings 


External Regulator, Internal Armature. 

Motor-Dynamo: Flywheel type, eight 
field coils, with series windings on 
four alternate poles and shunt wind¬ 
ings on intervening four poles. Four 
brushes. 

Controller: Single magnet operates 
cut-out and carbon disc regulator. 

Touring Switch: Opens and closes 
charging and field circuits. 

Starting Switch: Rotary drum com¬ 
mutating type. 

6 for charging and 12 for starting. 

16 to 18 amperes. 

Carbon disc field resistance. See sec¬ 
tion 465. 

Electromagnetic in controller. 

Motor-dynamo U2 right; external cir¬ 
cuits Ul. 






INTERNAL WIRING DIAGRAMS 


413 




A 








414 


STARTING AND LIGHTING TROUBLES 


U. S. L. 
Units 


Voltage 

Output 

Regulation 


Cut-out 

Fuses 


Inherent Regulation, 12-24 Volt. 

Motor-Dynamo: Flywheel type, eight 
field coils, eight brushes, shunt and 
series windings. 

Cut-out: Electromagnetic. Field fuse 
and charging fuse carried on cut-out. 

Touring Switch: Opens and closes 
charging and field circuit. 

Starting Switch: Rotary drum com¬ 
mutating type. , 

12 for charging and 24 for starting. 

12 to 13 amperes. 

Three lower brushes for generating. 
Field current controlled through 
armature reaction. 

Electromagnetic carried as separate 
unit. 

G ampere field fuse and 30 ampere 
charging fuse on cut-out. 

U3 


Drawing 



us Q 


INTERNAL, WIRING DIAGRAMS 


415 



\ 












































































416 


STARTING AND LIGHTING TROUBLES 


0. S. L. 
Units 



Voltage 

Output 

Regulation 


Cut-out 

Fuses 

Drawing 


1915 Motor-Dynamo, 12 Volt. 

Motor-Dynamo : Flywheel type; eight 
field coils; eight brushes; series, 
shunt and regulating field windings. 

Cut-out: Electromagnetic. Carries 

field and charging fuses. 

Touring Switch: Opens charging and 
field circuits. Incorporated with 
lighting and ignition switch unit. 

Starting Switch: On top of motor- 
dynamo. 

12 

12 to 15 amperes. 

Three lower brushes for generating. 
Field current controlled through 
armature reaction. 

Electromagnetic, carried as separate 
unit. 

6 ampere field fuse and 30 ampere 
charging fuse on cut-out. 

U4 




INTERNAL, WIRING DIAGRAMS 


417 














































































418 


STARTING AND LIGHTING TROUBLES 


U. S. L. 
Units 


Voltage 

Output 

Regulation 


Cut-out 

Puses 


Drawing 


1916 Motor-Dynamo, 12 Volt. 

Motor-Dynamo : Flywheel type; eight 
field coils; eight brushes; series, 
shunt and regulating field windings. 

Switch Unit: Includes cut-out; am¬ 
meter ; lighting switch; fuses for field 
current, charging current, main line 
and lighting lines; also starting but¬ 
ton. 

Starting Switch: On top of motor- 
dynamo. Operated by electromagnet 
energized by closing starting button 
on dash unit. 

12 

12 to 15 amperes. 

Bottom brush and one at its left for 
generating. Field current controlled 
by armature reaction. 

Electromagnetic carried in dash unit. 

All in dash unit. Field, 5 ampere; 
charging and main line, 30 ampere; 
lighting and horn, 10 ampere. 

U5 


s 


( 





INTERNAL WIRING DIAGRAMS 


419 



















































420 


STARTING AND LIGHTING TROUBLES 


VESTA Centrifugal Regulator. 

Units Dynamo: Permanent magnet type, two 

brushes. Centrifugal regulator on 
end opposite commutator. 

Voltage 6 

Output 5 to 6 amperes. 

Regulation Centrifugal regulator causes charging 

current to pass through more and 
more resistance as arm travels over 
segments under influence of centri¬ 
fugal weights of fly-ball type. See 
section 451. 

Cut-out Centrifugal, incorporated in regulator. 

: Segment against which arm rests 

with dynamo idle is disconnected 
from outside circuit. First contact 
touched, as arm starts to move, con¬ 
nects dynamo with battery. See sec- 
■ tion 451. 

Remarks This equipment is being rebuilt without 

the regulator. 

Drawing VI 




INTERNAL WIRING DIAGRAMS 


421 







































422 


STARTING AND LIGHTING TROUBLES 


VESTA 

Units 

Voltage 

Output 


Regulation 

Cut-out 

Drawing 


Permanent Magnet-Dynamo Without 
Regulator. 

Dynamo: Permanent magnet type, two 
brushes. Centrifugal cut-out on end 
opposite commutator. 

6 

“D2 5 ' machine: 1 amp. at 710 r.p.m. 
3 amp. at 930 r.p.m. 5 amp. at 1200 
r.p.m. 7 amp. at 1500 r.p.m. 10 amp. 
at 2200 r.p.m. 

4< F2” machine: 1 amp. at 1170 r.p.m. 
2 y% amp. at 1450 r.p.m. 3% amp. at 
1720 r.p.m. 5 % amp. at 2100 r.p.m. 
7% amp. at 2500 r.p.m. Proportion¬ 
ate intermediate values for both 
machines. 

Output uncontrolled except as effected 
by permanent magnet fields. 

Centrifugal, on end of dynamo opposite 
commutator. 

V2 


INTERNAL WIRING DIAGRAMS 
















424 


STARTING AND LIGHTING TROUBLES 


WAGNER 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Motor-Dynamo. 

Motor-Dynamo : Shunt and series wind¬ 
ings, four field coils. Two commu¬ 
tators, one at each end of armature. 
Each commutator has four brushes; 
one, offset, acting as regulating 
brush. 

Controller Box: Mounted on top of 
motor-dynamo and contains starting 
switch and cut-out. 

12 for charging and starting. Lights 
may be on three wire, 6 volt system. 

7 to 9 amperes. 

Third brush for shunt field current. 
See sections 413 to 419. 

Electromagnetic, carried in controller 
box on top of motor-dynamo. 

PI 




INTERNAL WIRING DIAGRAMS 


425 



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426 


STARTING AND LIGHTING TROUBLES 


WAGNER 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Fuses 

Drawing 


Separate Dynamo, 12 Volt. 

Dynamo : Shunt wound, four field coils, 
four brushes. Three generating 
brushes and one regulating brush. 

Cut-out: Electromagnetic, separate or 
on dynamo housing. 

Motor: Series wound, four pole, four 
brushes. 

Starting Switch: Double contact. Re¬ 
sistance in series on first contact. 

12 

7 to 9 amperes. 

Third brush for shunt field current. 
See sections 413 to 419. 

Electromagnetic with double set of con¬ 
tacts. 

Field fuse on dynamo housing. 

P2 


INTERNAL WIRING DIAGRAMS 


427 











































428 


STARTING AND RIGHTING TROUBLES 


WAGNER 

Units 


Voltage 

Output 

Regulation 

Cut-out 

Drawing 


Separate Dynamo, 6 Volt. 

Dynamo: Shunt wound. Two main 
brushes and one regulating brush. 

Cut-out: Electromagnetic, carried as 
separate unit. 

Motor: Series wound, four field coils, 
four brushes. 

Starting Switch: Single contact type. 

6 

14 to 18 amperes. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Electromagnetic. 

P3 


INTERNAL WIRING DIAGRAMS 


420 





































STARTING AND RIGHTING TROUBLES 


430 

WARD LEONARD. 

Units Dynamo : Shunt wound, two field coils, 

two brushes. 

Controller: Contains combined cut-out 
and current regulator. 

Voltage 6 or 12 

Output 10 amperes at 6 volts. 5 amperes at 

12 volts. 

Regulation Vibrating relay inserts field resistance 

to maintain constant current above 
certain speed. See sections 421 and 
429 to 431. 

Cut-out Electromagnetic, carried in same hous¬ 

ing with current regulator but hav- 

/ 

ing separate electromagnet and 

separate windings from regulator. 
Cut-out at left, regulator at right 
side of controller. 

WL1 


Drawing 


MU 


INTERNAL, WIRING DIAGRAMS 


431 



















































432 STARTING AND LIGHTING TROUBLES 

WESTINGHOUSE Ignition Dynamo, Separate Coil. 

Units Ignition-Dynamo : Shunt and reversed 

series wound, single field coil, two 
brushes. Cut-out on dynamo hous¬ 
ing. Ignition breaker on end oppo¬ 
site commutator. 

Coil Unit: Contains ignition coil, con¬ 
denser, switch and safety spark gap. 

Voltage 6 

Output See special table on last page of this 

section. 

Regulation Reversed series field winding. Turning 

lamps on diverts current from re¬ 
versed series coil and allows in¬ 
creased output. See sections 461 and 
476. 

Cut-out Electromagnetic, on dynamo housing. 

Drawing W1 


INTERNAL WIRING DIAGRAMS 


433 


























































434 STARTING AND LIGHTING TROUBLES 

WE STING HO USE Ignition-Dynamo, Coil in 


Unite 

Dynamo. 

Ignition-Dynamo: Shunt and reversed 
series wound, single field coil, two 
brushes. Cut-out on dynamo housing. 
Ignition breaker on end opposite 
commutator and ignition coil in 
dynamo housing. 

Motor: Series wound, two brushes. 

Starting Switch: Double contact; re¬ 
sistance in series on first contact. 

Voltage 

Output 

6 

See special table on last page of this 
section. 

Regulation 

Reversed series field winding. Turning 
lamps on diverts current from 
reversed series coil and allows in¬ 
creased output. See sections 461 and 
476. 

Cut-out 

Drawing 

Electromagnetic, on dynamo housing. 
W2 


INTERNAL WIRING DIAGRAMS 


435 


























































436 


STARTING AND LIGHTING TROUBLES 


WESTINGHOUSE Electromagnetic Switch and 

Pinion Shift. 

Units Dynamo: Shunt and reversed series 

windings. Single field coil, four 
: brushes. Cut-out on dynamo housing. 

Motor: Series wound, four brushes. 

Starting Switch: Mounted on motor 
and operated by solenoid which also 
moves pinion shift rod. This switch 
is of double contact type with re¬ 
sistance in series on first contact. 

Electromagnetic Switch: Connected 
between battery and starting switch. 
Contacts are closed by a solenoid 
energized by pressing a button type 
of switch. Current passing through 
this electromagnetic switch operates 
the main starting switch and pinion 
shift solenoid. 

Voltage 6 

Output ■ See; special table on last page of this 

section. 

Regulation Reversed series field winding. Turning 

lamps on diverts part of current from 
reversed series field and allows in¬ 
creased output. See sections 461 and 
476. 

Cut-out Electromagnetic, on dynamo housing. 

Drawing W3 


INTERNAL, WIRING DIAGRAMS 


437 































































438 


STARTING AND LIGHTING TROUBLES 


WESTINGHOUSE Electromagnetic Starting 

Switch. 

Units Dynamo: Shunt and reversed series 

wound, single field coil, two brushes. 
Cut-out on dynamo housing. 

Motor: Series wound, two brushes. 

Starting Switch: Contacts are closed 
by a solenoid energized by pressing 
a button type of switch. 

Voltage 6 

Output See special table on last page of this 

section. 

Regulation Reversed series field winding. Turning 

lamps on diverts part of current from 
reversed series field and allows in¬ 
creased output. See sections 461 and 
476. 

Electromagnetic, on dynamo housing. 

.W4 


Cut-out 

Drawing 


INTERNAL# WIRING DIAGRAMS 


439 



































440 


STARTING AND LIGHTING TROUBLES 

WESTING-HOUSE Constant Voltage, Controller in 

Dynamo. 

Units Dynamo: Shunt wound, single field 

coil, two brushes. Cut-out and volt¬ 
age regulator carried on dynamo 
housing. 

Voltage 6 

Output 4 to 15 amperes, depending on voltage 

of battery. With a fully charged 
battery the output is low; with a dis¬ 
charged battery the output is high. 

Regulation Constant dynamo voltage maintained 

by vibrating relay inserting shunt 
field resistance. See sections 422 and 
429 to 431. 

Cut-out } Electromagnetic, combined with voltage 

regulator and mounted on dynamo 
i housing. 

Drawing ]W5 


INTERNAL, WIRING DIAGRAMS 


441 









































442 


STARTING AND LIGHTING TROUBLES 


WESTINGHOUSE Constant Voltage, Separate Con 

troller. 


Units 

Dynamo : Shunt wound, four field coils, 
two brushes. 

Controller: Combined electromagnetic 
cut-out and constant voltage regu¬ 
lator carried as a separate unit. 

Motor: Series wound, four field coils, 
four brushes. 

Voltage 

Output 

6 

4 to 15 amperes, depending on voltage 
of battery. With a fully charged 
battery the output is low; with a dis¬ 

Regulation 

charged battery it is high. 

Constant dynamo voltage maintained 
by a vibrating relay inserting shunt 
field resistance. See sections 422 and 
429 to 431. 

Cut-out 

Electromagnetic, combined with voltage 
regulator and carried as a separate 
unit. 

Drawing 

W6 


INTERNAL. WIRING DIAGRAMS 


443 













































444 STARTING AND LIGHTING TROUBLES 

WESTINGHOUSE Third Brush System, Cut-out in 

Dynamo, 


Units 

Dynamo: Shunt wound, four field coils, 
two main brushes and one regulating 
brush. Cut-out and field fuse in 

* 

dynamo housing. 

Motor: Series wound, four field coils, 
four brushes. 

Voltage 

Output 

Regulation 

6 

12 to 14 amperes maximum. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Cut-out 

Electromagnetic, carried in dynamo 
housing. 

Fuses 

Drawing 

Field fuse carried in dynamo housing. 
W7 



INTERNAL WIRING DIAGRAMS 


445 























446 


STARTING AND LIGHTING TROUBLES 


WESTINGHOUSE Third Brush System, Separate 

Cut-out. 

Units Dynamo : Shunt wound, four field coils, 

two main brushes and one regulating 
brush. 


Voltage 

Output 

Regulation 

Cut-out 

Fuses 

Drawing 


6 

12 to 14 amperes maximum. 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Electromagnetic, carried as a separate 
unit. Field fuse mounted on cut-out. 
Field fuse carried on cut-out. 

W8 


INTERNAL WIRING DIAGRAMS 


447 



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I 



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o» 


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448 STARTING AND LIGHTING TROUBLES 

WESTINGHOUSE Motor-Dynamo. 

Units Motor-Dynamo: Shunt and series 

wound, two field coils, two main 
brushes and one regulating brush. 

Starting Switch: Single contact. Cut¬ 
out in starting switch housing. 

Voltage 12 

Output 8 amperes maximum. 


Regulation 

Third brush for field current. See sec¬ 
tions 413 to 419. 

Cut-out 

Electromagnetic, carried in starting 
switch housing. 

Drawing 

W9 


INTERNAL WIRING DIAGRAMS 


449 










































450 


STARTING AND LIGHTING TROUBLES 


WESTINGHOUSE Output Rates. 

Showing amperes delivered by reversed 
series separate dynamos and ignition- 
dynamos of the following frame 
numbers: 

Amperes 

“A,” “B,” “202,” “203,” etc. 12 


“208” 13 

“230” 17 

“236” 15 

“240” 10 

“246” 71/2 

“251” to “255,” “280,” etc. 10 

“520,” “521,” etc. 11 




INDEX 

A 

A. B. C. equipment.238 

Adjustment (see name of type) 

Adlake regulation. 175 

specifications and wiring.240, 241 

Allis-Chalmers specifications and wiring.242, 243 

Ammeter . 44 

tests with. 46 

using. 36 

Amperage of dynamo, test of.110 

Ampere-hour meter regulation.173 

Apelco (see Splitdorf and Aplco) 

Aplco regulation .177 

specifications and wiring.244, 249 

Armature, bearings loose in.132 

examination of.114 

examination of starting.193 

grounded .128 

open circuited.129, 130 

short circuited.129, 131 

trouble, motor.200 

trouble, symptoms and remedies.128 

Autolite regulation.165 

specifications and wiring.250-257 

B 

Battery, capacity for lighting.232 

capacity for starting.232 

care of.214 

charge and discharge of.219 

cleaning .212 

connections for.215 

mounting of.215 

testing! the.221 

trouble in. 210 

Belt drive..... 149 

Bendix drive.207 


451 




































452 


INDEX 


Bijur specifications and wiring.258-263 

Bosch regulation.174 

specifications and wiring.264-269 

Breaker, circuit, trouble in.,108 

Briggs-Nash specifications.23S 

Brush circuit open.121 

contact .118 

examination .113 

examination, starting.192 

holders .120 

material .122 

position .122 

size .122 

sparking ....114 

spring tension . 120 

squeaks .123 

trouble, motor .199 

trouble and remedies.117 


Bucking coil (see reversed series) 
Bulb, lamp (see lamp) 


C 


Cam controlled regulation. 

Candlepower of lamps. 

Capacity, required battery 
Centrifugal governors .... 

Chain drive . 

Charge of battery. 

Chart A . 

B . 

C . 

D . 

E . 


G 

H 

I 

J 

K 

L 

M 

N 

O 

P 


.181 
.101 
.232 
.163 
.207 
.219 
. 13 
. 13 
. 14 
. 15 
. 16 
. 17 
. 18 
. 19 
. 20 
. 21 
. 22 
. 24 
. 26 
. 28 
. 31 
. 32 











































INDEX 453 

Charts, outline of. 12 

Circuit, open (see open circuit) 

Circuit, short (see short circuit) 

breaker trouble .108 

Clutch, overrunning.208 

Commutator (see also armature).123 

bars loose.126 

dirty .123 

examination . 113 

examination, starting.193 

rough .124 

trouble, motor.199 

trouble and remedies.123 

undercutting of.125 

Compound field regulation.169 

Conductors (see wiring) 

Connector, wiring, trouble in.102 

Control (see regulation) 

Constant current regulation.157 

Constant speed regulation. 163 

Constant voltage regulation.158 

Current, lamp.231 

polarity test. 79 

Cut-out, adjustment of.186, 188 

closing time of.186 

manual type of.189 

opening time of.188 

sticking .184 

trouble, symptoms and remedies.183 

D 

Deaco regulation. 178 

specifications and wiring.238, 270, 271 

Delco regulation.165, 173, 176 

specifications and wiring.272-295 

Detroit-Ward Leonard specifications and wiring... .296-299 

Discharge of battery.219 

Disco specifications and wiring.238, 300-303 

Drive, belt.149 

trouble in.206 

Driving conditions for dynamo.148 

Dynamo, bearings loose in. 132 

drive for (see drive ) 

examination, of.113 






































454 


INDEX 


heating of.115 

motoring test of.115 

output test of.110 

trouble in.109 

Dyneto specifications and wiring.304-311 


E 


Eisemann specifications.238 

Electrolyte of battery.210 

Electro specifications.238 

Electro-magnet polarity test. 82 

Entz specifications and wiring.312, 313 

Esterline regulation.178 

Esterline specifications and wiring.314-317 


Field current while motoring.135 

demagnetized .142 

fuse burned out.136 

grounded .139 

open circuited.138 

poles loose.145 

resistance high.138 

reversed .142, 144 

short circuited.140 

tests .134 

trouble, motor.:.201 

trouble, symptoms and remedies.134 

Fisher specifications.238 

Focus of lamp bulbs. 94 

Ford specifications and wiring.318-321 

Fuse, field, burned out.136 

lighting, size of.107 

lighting, trouble in.106 


G 


Garford specifications and wiring.322, 323 

Genemotor specifications.238 

Generator (see dynamo) 

Gray & Davis regulation.164 

Gray & Davis specifications and wiring.324-335 

Ground, accidental. 58 






































INDEX 455 

Ground, test for. 70 , 73 

Grounded armature. .128 

cut-out . 183 

field .139 

starting switch. 204 

wiring. 83 

wiring, test for. 84 

wiring, table of tests. 85 

wiring, table of causes and remedies. 89 

H 

Hartford specifications and wiring.336, 337 

Heating of dynamo.115 

Heinze specifications and wiring.338-341 

High resistance. 57 

test . 62 

test table. 66 

in field.138 

in starting switch.203 

in wiring. 83 

in wiring, test for. 93 

in wiring, table of causes and remedies. 93 

Housing, dynamo, examination of.114 

I 

Inspection, tests by. 35 

Instruments for testing. 34 

Instruments used in tests.52 

Iron wire regulation.171 

J 

Jesco regulation.178, 179 

specifications and wiring.342-347 

K 

Kemco specifications.239 

L 

Lamp, bulb trouble in. 99 

candlepower of. 101 

































456 


INDEX 


connector trouble in.102 

current required by..231 

focusing . 94 

high voltage, tests with. 49 

low voltage, tests with. 49 

reflector tarnished in. 96 

socket trouble in.102 

trouble, table of.'.. 98 

use of.103 

Lauraine specifications.239 

Leece-Neville specifications and wiring.348-353 

Lighting, fuse trouble.106 

switch trouble.105 

system trouble. 94 

Load test.58, 75 

M 

Magnetic polarity test. 80 

Manual cut-out.189 

Motor armature trouble.200 

Motor, brush trouble in.199 

commutator trouble in. 199 

drive for (see drive) 

field trouble in.201 

power test of.197 

running free test of.195 

Motoring test of dynamo.<.115 

N 

National specifications.-.239 

North East specifications and wiring.354-363 

O 

Ohm’s law.227 

Open circuit. 57 

test in parallel. 60 

test in series. 59 

testing table. 62 

Open circuited armature.129, 130 

brush .121 

cut-out.183, 185, 186 

field.138 





































INDEX 


457 


starting switch.203 

wiring .83, 89 

wiring, table of causes and remedies. 92 

wiring, table of tests. 90 

Output (see name of equipment) 

of dynamo, test of.110 

Overrunning clutch.208 

P 

Polarity tests.58, 79 

Pole pieces loose.145 

R 

Regulation (see name of equipment) 

cam controlled.181 

centrifugal .163 

compound field.169 

constant current.157 

constant speed.163 

constant voltage.158 

load control.158 

reversed series.159, 169 

third brush.150 

troubles in.148 

vibrating relay.155 

Relay air gap adjustment.160 

regulation, vibrating.155 

spring adjustment. .160 

Remy regulation.169 

specifications and wiring.364-385 

Resistance, copper wire.228 

high (see high resistance). 57 

test of.58, 76 

Reversed series regulation.159, 169 

Rex specifications.239 

Rushmore regulation.171 

specifications and wiring.386-389 

S 

Screw pinion shift trouble.207 

Short circuit. 58 

test.67, 73 

test table.70, 75 





































458 


INDEX 


Short circuited armature.129, 131 

cut-out .183 

field.'....140 

starting switch.204 

wiring . 83 

wiring, test for. 84 

wiring, table of tests. 85 

wiring, table of causes and remedies. 89 

Simms-Huff specifications and wiring..390-397 

Socket, lamp, trouble in.102 

Sparking at brushes.114 

at starting brushes.194 

Specific gravity tests.221 

Speed regulation.163 

Splitdorf specifications and wiring.398-409 

Splitdorflite specifications. 239 

Spring tension of brushes.120 

Squeaking brushes.123 

Starting motor (see motor) 

Starting switch (see switch) 

Starting troubles.192 

Switch, lighting, trouble in.105 

starting, trouble in.201 

starting, types of.205 

Symbols, wiring diagram.224, 225, 226 

T 

Tests, ammeter. 46 

high voltage lamp. 49 

list of. 52 

low voltage lamp. 49 

voltmeter . 41 

Thermostat regulation.169 

Third brush adjustment.151, 155 

regulation .150 

Torque, starting and running.235 

U 

Undercutting commutator mica.125 

U. S. L. regulation. 173 

specifications and wiring. 410-419 






































INDEX 


459 


V 


Vesta regulation.168 

specifications and wiring.420-423 

Vibrating relay regulation.155 

Voltage, battery, testing.222 

dynamo, testing.112 

loss test. 58 

Voltmeter . 37 

connections for . 41 

tests with. 41 

using. 36 


W 


Wagner specifications and wiring .424-429 

Ward Leonard specifications and wiring.430, 431 

Wells specifications.239 

regulation .180 

Westinghouse regulation.180 

specifications and wiring.239, 432-450 

Wire, minimum size for lighting and charging.229 

minimum size for starting.231 

resistance of.228 

Wiring diagrams (see name of equipment) 

diagram symbols.224, 225, 226 

test table. 84 











































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